Designing an efficient layout for your warehouse will simplify the workflow and shorten unnecessary shipping and transportation time.

However, if you can not effectively use and store the space provided, it will negatively impact the workflow, supply chain, and shipping time.

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Therefore, you will have to design or redesign the layout of the warehouse carefully to optimize productivity and performance. Whether you are the manager running a warehouse or own a new warehouse, there is no one-size-fits-all method for a warehouse design.

Redesigning a warehouse can be a daunting and tiring process as there are numerous aspects to consider, such as warehouse shelving layout etc. An essential element is to have a solid game plan of your vision and what you would like to achieve by redesigning the warehouse.

Here are a few suggestions on designing a warehouse layout to enhance the warehouse and its maximum capacity and improve revenue.

Your game plan should include the following:

1. Determine the outline

Take a pencil and paper, walk through the warehouse and design a floor plan. If an existing layout for the warehouse is available, you can refer to that layout or create your new map.

Two great alternatives if you don't want to take the time and design a layout on paper is to search online and use software specifically developed to create a warehouse layout design. Or, hire a professional warehouse designing expert who can map your warehouse and optimize the layout according to your needs and specifications.

Whatever you do, it is vital to understand that this is not the time to take any shortcuts as the workspace in the warehouse must be measured as close to the accurate measurements as possible to achieve the best results.

Remember to include walk paths, the height of internal structures and the flow of shipments and products. Mark each area clearly to indicate how the warehouse will look when completed and determine if changes need to be made.

Should business operations later change and the layout needs to be modified, don’t stress. Using industrial curtains, you can easily add new partitions as needed.

Once the layout has been established, the warehouse space has to be optimized.

2. Planning The Space

The number of spaces available inside the warehouse will ultimately determine how the layout will be mapped. So, first, decide how your products will be stored, then plan your storage area. 

 Keep in mind that the workflow area, reception, and equipment that will be used need to be considered. An adjustable platform should be in the plan as it is a great way to increase storage area height and the amount of shelves that can be used.

3. Separate the loading and unloading areas

Having both the loading and unloading of product areas in one area or close to each other may create potential chaos in the warehouse as employees might get confused about which products should go where.

Therefore, it is imperative to keep both areas separate from each other.

Choosing the correct equipment is critical to ensure that your warehouse runs smoothly, regardless of what your warehouse is used for.

There are various types of equipment and machines available to operate the warehouse processes and procedures effectively. However, these machines, such as forklifts and pallet trucks, may limit the amount of space in the warehouse. For example, most forklifts require aisle space in width of about 12 feet minimum.

4. Choosing Efficient Equipment

Pallet Jack & Pallet Inverter

Whether you’re moving pallets or heavy-duty plastic pallet boxes, pallet jacks are considered to be an essential piece of equipment to ensure effective warehouse operations. There are two types of pallet trucks available: manual and electrical pallet trucks used to transport smaller crates and loads over short distances.

Although operating a pallet truck might sound like an easy and simple task, you need to make sure that all staff know how to handle and correctly use this machine to avoid employee injuries, any damage to the equipment and potential loss of products.

Once the pallet gets to where it needs to be, a pallet inverter will easily invert pallets and is an essential piece of equipment to reduce product damage and workplace injuries. It will keep productivity humming and the warehouse organized.

Ensure to provide all of your employees with efficient and appropriate training with all heavy equipment, as safety should be the top priority in all warehouses.

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Forklifts

A forklift is one of the essential and most popular types of machinery used for warehouse operations. Forklifts have various benefits to ensure the functions of the warehouse are executed effectively. They are considered the most suitable indoor equipment to move pallets and crates around, bulky transportation of goods, and help employees transport products around the warehouse more comfortably.

Practicing and implementing the correct forklift safety regulations is imperative to prevent any onsite injuries and lawsuits. Renting a warehouse forklift for eternal companies may be more economical and cost-effective, but purchasing your own warehouse forklifts must be a goal as it will ultimately benefit your company.

5. Layout Designs Proposals

The optimization of the warehouse design can improve operations tremendously. However, as mentioned previously, there is no one size fits all layout design. Therefore, considering these layout designs suggestions might make the process a bit easier.

I - Shaped Layout

The I-shaped warehouse layout is very suitable for large capacity warehouses. Also known as the flow-through design, it is shaped like an "I" with the warehouse and storage area in the middle, a loading dock at one end and an unloading dock at the other end.

With the higher volume stock easily accessible, the products are delivered at the unloading dock of the warehouse, where they are moved and processed through the middle of the warehouse to the loading dock, ready for distribution.

Thus, providing continuous flow throughout the warehouse.

U - Shaped Layout

As the warehouse is shaped like a semicircle, U-shape, this layout is considered the most favourable design of all. Furthermore, because of its simplistic and uncomplicated design, a U-shape warehouse layout can be replicated anywhere in the warehouse as it makes the most of any warehouse space.

Warehouse owners recommend placing the loading and unloading docks on each side of the U-shape and your stock in the storage area behind the warehouse.

L-Shaped Layout

The primary benefit of the L-shape design is that there will be ample storage space that you can fill up with products as the loading and unloading docks will be stations on each side of the L-shape layout.

6. Test The Layout Plan

Before hiring experts to build the interior and warehouse shelving layout, it is recommended first to test your design and vision. Take a walk through your plan, set up the perimeter, and determine if your design will work in the amount of space in your warehouse.

While running this test, it will be best to use the equipment and machines around the perimeters as if you are in operation and see if the workflow is efficient enough to move freely without any obstructions and potential hazards.

Include your employees in this test as they will be the ones who have to work in and around the warehouse. Allow them to give feedback and make suggestions to enhance and improve the space and design possibilities.

Take careful notes and record the whole testing process to know where to improve and change the layout if needed. Should your plan need adjustments, be sure to modify it accordingly. It is best to make the necessary changes before the building and set-up process starts instead of going back to the drawing board later.

Once the warehouse design has been established and renovations have started, another crucial element to implement is the safety of your employees and all ground workers.

Staff Safety Gear

The protection and safety of all employees are vital for all warehouse operations. Be sure to provide all staff members with the correct and appropriate safety gear from head to toe.

The goal of the warehouse design is to optimize space meaning, products, and containers will be stored above head level. All staff members should have a safety helmet, eyewear, ear protection, gloves and reflectors vests.

Layering the floor print of your warehouse with industrial floor mats will be beneficial as it will absorb any impact and reduce possible strain on your employee's shins, knees and ankles.