Last updated on 2024年6月4日

What are the common warehouse layout mistakes and how to avoid them?

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Warehouse layout design principles are essential for efficient and safe operations in logistics management. A well-designed warehouse can optimize the flow of goods, reduce costs, improve customer service, and prevent accidents. However, many warehouse managers make common mistakes that can compromise their performance and profitability. In this article, we will discuss some of these mistakes and how to avoid them.

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1 Mistake 1: Ignoring the warehouse objectives

One of the biggest mistakes warehouse managers make is not aligning their layout design with their warehouse objectives. Different types of warehouses have different functions and requirements, such as storage, picking, packing, shipping, receiving, or value-added services. Therefore, the layout design should reflect the specific needs and goals of each warehouse, such as maximizing space utilization, minimizing travel distance, enhancing productivity, or ensuring quality control. A generic or outdated layout design can result in wasted space, inefficient processes, low service levels, or high operational costs.

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Richard Gonel

Senior Logistics Analyst @ AVNIK Defense Solutions, Inc. | PdM ACMC Fleet Fielding Manager
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We’re in the process of redesigning one of our warehouses. Understanding that one of the warehouses is used as storage and distribution of those stored materials means that we can use more vertical space instead of having it mid height like the others.

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Craig Andrews

Warehouse Development leader at GEA Group
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Layout of a warehouse is critical to the flow, and reduction of bottle necks. Your top 100+ moving products should be on the closest pick face to the despatch packing stations. Always apply lean principles, there is always room for improvement.

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2 Mistake 2: Neglecting the warehouse inventory

Another common mistake warehouse managers make is not considering their warehouse inventory when designing their layout. The warehouse inventory includes the types, sizes, weights, quantities, and turnover rates of the products stored in the warehouse. These factors affect the choice and configuration of the storage equipment, such as racks, shelves, bins, or pallets. The warehouse inventory also influences the layout of the aisles, zones, and workstations, as well as the allocation of the storage locations. A poor inventory management can lead to overstocking, understocking, misplacement, or damage of the products.

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Steven Filiatrault

Railroad Operations, Maintenance, Expansion, Rehabilitation and Development Contractor
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Watch for how the intended materials are palletized, and don’t forget to look at the pallets themselves for proper weight distribution to the storage rack, and good structural integrity. Center of gravity and choices of picking equipment are also important

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3 Mistake 3: Overlooking the warehouse operations

A third common mistake warehouse managers make is not taking into account their warehouse operations when designing their layout. The warehouse operations include the activities, processes, and procedures that take place in the warehouse, such as receiving, putaway, picking, packing, shipping, or replenishment. These operations determine the flow and direction of the goods, the movement and interaction of the workers, and the utilization and maintenance of the equipment. The warehouse layout should facilitate and support the warehouse operations, by minimizing congestion, confusion, or conflicts, and by ensuring safety, security, and compliance.

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4 Mistake 4: Failing to optimize the warehouse space

A fourth common mistake warehouse managers make is not optimizing their warehouse space when designing their layout. The warehouse space refers to the physical dimensions and characteristics of the warehouse, such as the floor area, the ceiling height, the column spacing, the lighting, or the ventilation. The warehouse space affects the capacity and flexibility of the warehouse, as well as the comfort and health of the workers. The warehouse layout should maximize the use of the available space, by eliminating or reducing any wasted or unused space, and by adjusting or adapting to any changes or constraints.

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5 Mistake 5: Resisting to change the warehouse layout

A fifth common mistake warehouse managers make is not changing their warehouse layout when necessary. The warehouse layout is not a static or fixed element, but a dynamic and evolving one. The warehouse environment is constantly changing, due to factors such as market demand, customer preferences, product innovations, or technological advancements. The warehouse layout should respond and adapt to these changes, by reviewing and evaluating its performance, by identifying and implementing improvements, or by redesigning and reconfiguring its components.

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6 How to avoid these warehouse layout mistakes

To avoid warehouse layout mistakes, warehouse managers should conduct a thorough analysis of the warehouse objectives, inventory, operations, and space before designing or modifying the layout. It is important to choose and arrange the storage equipment, aisles, zones, and workstations according to the characteristics and requirements of the products and processes. Additionally, a logical and consistent flow of goods and people should be created and maintained from the receiving to the shipping area, and from the storage to the picking area. Utilizing the vertical and horizontal space efficiently is also essential, by using appropriate storage systems, equipment, and techniques. Furthermore, warehouse performance should be monitored and measured by using key performance indicators, such as space utilization, travel distance, productivity, or service level. Finally, feedback and suggestions from the warehouse workers, customers, suppliers, or experts should be sought and applied to improve the warehouse layout and operations.

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Anatoly Fishgang
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It's very hard to take into account all the issues mentioned above. From experience, I think the best way is to simulate warehouse with digital twin tools.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Tom Edholm

Highly experienced supply chain leader that just gets results. I can provide dynamic supply chain consulting, worldwide sourcing and major cost reduction.
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Some Mistakes we see are not looking at the warehouse in totality. It's a big puzzle and there are different strategies for different parts due to size, restrictions, movement or mode of transportation. Another mistake is not slotting often enough, especially with highly seasonal items. Your fastest moving items might significantly change throughout the year. You should re-slot heading into a new season. Finally, get creative and look around. Can you maximize density by varying bin sizes or could I put racks above the dock doors that's typically wasted space?

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What are the common warehouse layout mistakes and how to avoid them?

1

2

3

4

5

6

7

1 Mistake 1: Ignoring the warehouse objectives

2 Mistake 2: Neglecting the warehouse inventory

3 Mistake 3: Overlooking the warehouse operations

4 Mistake 4: Failing to optimize the warehouse space

5 Mistake 5: Resisting to change the warehouse layout

6 How to avoid these warehouse layout mistakes

7 Here’s what else to consider

Logistics Management

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What are the common warehouse layout mistakes and how to avoid them?

1

2

3

4

5

6

7

1 Mistake 1: Ignoring the warehouse objectives

2 Mistake 2: Neglecting the warehouse inventory

3 Mistake 3: Overlooking the warehouse operations

4 Mistake 4: Failing to optimize the warehouse space

5 Mistake 5: Resisting to change the warehouse layout

6 How to avoid these warehouse layout mistakes

7 Here’s what else to consider

Logistics Management

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