Program Overview
This intensive program helps warehouse and supply chain professionals design high-performance storage layouts that reduce handling time, optimize space, and improve inventory access. Participants learn how to apply principles of flow-through design, ABC-based slotting, SKU velocity mapping, and warehouse zoning. The program covers various racking types, aisle configurations, picking strategies (single vs. batch vs. wave), and layout considerations for different product types (palletized, carton, bin). Through real-world case studies and simulations, the course empowers participants to redesign warehouse space for higher throughput and lower cost per pick.
Features
- Design warehouse layouts to support flow, efficiency, and safety
- Apply ABC/velocity-based slotting to reduce travel time and picking effort
- Choose appropriate racking and MHE setups based on product profiles
- Calculate space utilization and identify layout improvement opportunities
Target audiences
- Warehouse Managers
- Supply Chain Planners
- Industrial Engineers
- 3PL Operations Teams
- Facility Designers
Curriculum
- 5 Sections
- 25 Lessons
- 1 Day
Expand all sectionsCollapse all sections
- Warehouse Layout Planning – Fundamentals & Types5
- 1.1Concepts: Layout principles (flow, accessibility, flexibility, scalability)
- 1.2Keywords: U-flow vs Through-flow, Grid Layout, Receiving Zone, Cross Dock Area
- 1.3Layout Types: Ambient vs Temperature-Controlled, Multi-tier, ASRS-Enabled
- 1.4Real-life Case: Food distributor redesigned layout to reduce pick path by 40%
- 1.5Toolkit: Layout Planning Checklist – capacity, flow, access, MHE compatibility
- Zone Design & Material Flow Optimization5
- 2.1Zones: Receiving, Put-away, Fast-Moving, Bulk, Buffer, Value-Added Services, Dispatch
- 2.2Keywords: Dock-to-Stock, Aisle Width Optimization, FIFO/LIFO Zoning, Work Triangle
- 2.3Situational Focus: Frequent re-handling due to poorly placed buffer zones
- 2.4Case Study: Auto spares DC increased dispatch throughput with dynamic staging lane
- 2.5Framework: Draw ideal zone flow for given SKU profile
- Slotting Principles & SKU Profiling4
- 3.1Concepts: Velocity-based slotting, ABC analysis, SKU turnover vs volume
- 3.2Keywords: Golden Zone, Pick Density, Zoning Matrix, SKU-Location Matching
- 3.3Case Study: Electronics warehouse optimized picker travel using golden zone mapping
- 3.4Toolkit: Slotting Simulator – assign 20 SKUs to 10 zones based on heat map
- Space Utilization & Storage System Selection5
- 4.1Concepts: Cubic Utilization, Clear Height, Racking Types (Selective, Double Deep, VNA, Drive-In)
- 4.2Keywords: Pallet Pattern, Utilization %, Pick Face, Put-away Time
- 4.3Situational Focus: Increasing SKU base without increasing warehouse footprint
- 4.4Real-life Insight: Pharma firm adopted vertical space with VNA to defer capex
- 4.5Decision Matrix: Select racking/storage system based on product profile
- Capacity Planning, Simulation & Optimization Tools6
- 5.1Concepts: Storage vs Throughput trade-off, demand-based zoning
- 5.2Keywords: Heat Maps, Dynamic Slotting, Simulation Tools, Space Modeling
- 5.3Case Study: Beverage company used simulation software to reassign SKUs by volume & weight
- 5.4Capacity planner
- 5.5SKU-to-slot allocation matrix
- 5.6Space utilization dashboard
Instructor
