Warehouse planning: The comprehensive guide to an efficient warehouse structure
Whether you are a small company or a large corporation, well-organised warehouses and well-thought-out storage processes are the key to smooth operations and cost-effectiveness. Find out here what is important when planning a warehouse and how BITO Storage Systems can help you optimise your storage with a range of innovative solutions.
Analysis of requirements as a basis for optimising warehouse processes
Type of warehousing and logistics processes
What are the objectives of the warehouse and what processes will take place there? Is it primarily about controlling material flows in your own company, are incoming and outgoing goods at the forefront, or should the warehouse serve both purposes equally? The type of goods and products determine which warehousing strategy is used.
Storage and transport technology
What types of storage units do you typically deal with, how large and heavy are they, and what quantities are involved? Is it bulk or general cargo? Would you like to maximise your storage capacity by using flat-floor racks, sloping-floor racks or cantilever racks? Are normal shelving systems sufficient, or are Heavy-Duty Racks required? Should special areas be set up for picking? The answers to these questions will help you determine the space and other requirements for the warehouse, and optimising them will make warehousing processes more efficient.
If you want to calculate the storage area for non-stackable goods, then you can proceed as follows:
- Multiply the length and width of each storage unit to determine their floor areas.
- Determine the total storage area by multiplying the floor areas by the number of storage units.
For stackable goods, determine the maximum height to which you can safely stack the storage units. Then divide the number of storage units by the planned number of storage units per stack and multiply the result by the floor space. With special tools and software, you can make capacity planning easier and optimise your warehouse processes in a targeted way.
The floor plan of the warehouse
The last step in warehouse planning is to develop a warehouse layout that takes into account all the factors mentioned and coordinates them in the best possible way. First, sketch out a rough floor plan for the positioning of the various storage areas. Based on this, determine the alignment of shelves, service routes and conveyor technology in the second step.
Optimise warehouse layout: How to successfully arrange the warehouse space
By optimising shelving systems and designing efficient traffic routes and picking zones, you can shorten access times to stored items and increase warehouse throughput. Automated storage systems with storage and retrieval machines contribute to optimising warehousing in the same way as sophisticated storage area management with a warehouse management system (WMS).
Optimise storage processes with the right shelving systems
If you want to optimise your warehouse processes and make them more efficient, then racking systems such as BITO pallet racking offer a range of advantages. For example, they allow you to make better use of the height of your warehouse and thus maximise the available storage space. What's more, pallet racking ensures that goods are neatly arranged, making them easier to identify and access.
As pallet racks are modular, they offer maximum flexibility and can be easily adapted to changing needs. Thanks to their robustness and stability, they help to make warehouse processes safer and minimise the risk of accidents and damage. They are also compatible with automated storage systems and conveyor technology, which makes it easier to automate warehouse processes.
Integration of modern technologies
The integration of advanced technologies has revolutionised both warehousing and the logistics industry. With intelligent intralogistics solutions, you can optimally map the increasingly complex flows of materials and goods, plan more efficiently, optimise storage space and warehouse processes, and save costs.
The Internet of Things (IoT) enables real-time monitoring of stock levels, machines and environmental conditions. Automation solutions such as robots can increase efficiency and safety by performing routine tasks such as stocking shelf systems and picking trolleys or transporting containers with hazardous substances. Furthermore, warehouse management systems provide a central platform for managing the entire warehouse logistics.
Safety and environmental aspects in optimising warehouse processes
If you want to optimise warehouse processes, you need to observe various safety guidelines and environmental regulations. Occupational safety is just as important as energy efficiency, sustainability and waste management.
The most important safety aspects at a glance
The following occupational safety and security precautions are important when organising a warehouse:
- ensuring the correct handling and storage of hazardous substances in accordance with legal requirements
- providing personal protective equipment such as helmets, safety shoes and gloves
- designing ergonomic workplaces to minimise the strain on warehouse staff and avoid health problems
- Implementing fire protection measures such as fire alarms, fire extinguishers and emergency exits
- Regularly inspecting all machines and equipment to prevent accidents
- Regularly instructing and training employees in safety procedures and emergency measures
Environmental aspects of warehouse optimisation
Companies that focus more on environmental protection and sustainable storage solutions often save costs and at the same time benefit from an improved image and higher employee satisfaction. In addition, sustainable practices can be a unique selling point and give you an advantage over competitors. Possible strategies include:
- Energy savings through modern technologies such as energy-efficient lighting and air conditioning systems
- Systems to monitor and reduce energy consumption
- recycling programmes to reduce waste and increase the reuse of materials
- use of sustainable building materials in the construction and renovation of warehouses
- use of renewable energy sources such as wind or solar energy to meet the energy needs of warehouse operations in the most environmentally friendly way possible
Best practices for efficient warehouse structures: How to avoid common mistakes
When optimising the storage process, various errors can occur that have a negative impact on both efficiency and safety.
Bad layout
An inefficient warehouse layout impairs the material flow and reduces productivity. That is why you should pay full attention to this aspect and devote due care to it. You should also have warehouse processes analysed by experts before planning any optimisation.
Insufficient technology integration
The use of modern technologies boosts the efficiency and safety of warehouse processes. By integrating IoT, AI and automation systems, you increase your chances of staying ahead of the competition.
Missing inventory management
Inadequate inventory tracking can result in overstocks and stockouts. A warehouse management system that monitors your inventory in real time can help.
Incorrect capacity calculations
If you plan a warehouse or production facility that is larger than necessary, you will need more space, personnel and resources. This increases warehousing costs. Conversely, a lack of space can make time-consuming and costly expansions or relocations necessary. Other possible consequences are:
- Complicated strategic planning, which can lead to suboptimal decisions and investments
- Insufficient flexibility to effectively respond to market changes and shifts in demand
- Higher risk of obsolete stock taking up unnecessary space
- Loss of sales and reputation if products are not delivered on time
- Increased risk of accidents due to restricted movement and blocked emergency exits
- Higher energy consumption and thus greater environmental impact
If you want to be on the safe side when planning your warehouse, then you should seek advice from specialists on the right steps to take. These experts are familiar with best practices and pitfalls and know how they can accelerate warehouse processes and make them more efficient through holistic optimisation.
Conclusion: well-thought-out warehouse processes help to overcome logistical challenges.
Careful planning of your warehouse is crucial to making your warehousing processes efficient and sustainable and to meeting growing logistical demands in the future. Choosing the right premises is just as important as selecting the right shelving systems and a suitable management system. The tips in our warehouse planning guide provide a basic orientation.
If you need more extensive support, our experts will be happy to help you to make your warehouse processes more efficient by means of systematic optimisation. Contact us right away and get comprehensive and individual advice.