Curriculum
- 5 Sections
- 25 Lessons
- 1 Day
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- 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