Space management is often a critical factor in warehouses. It is not just a question of having enough space when there are peaks in demand and more goods than usual come in, but also of how these goods are distributed so that their location and access are as efficient as possible.
This is why the layout of a warehouse is fundamental to a company’s logistics management. In a nutshell, it defines the distribution of space and the choice of physical elements such as pallets, shelves and forklifts. It also includes key areas such as receiving, storage and dispatch. There are different types of layouts depending on the type of warehouse.
What is a warehouse layout?
A warehouse layout is the planned distribution that defines the structure and physical organization of the available space, in order to optimize its use and improve efficiency in logistics management.
Advantages of a planned warehouse layout
The warehouse layout plays a fundamental role in the logistics management of a company. An efficient and well-planned layout allows for better control and handling of goods. Among the main advantages are: 1. Reduction of search and travel time.
2. Reduced risk of damage, loss or errors in inventory management.
3. Improved access to stored products, speeding up loading and unloading operations, thus improving delivery times.
4. Greater flexibility to adapt to changes in demand.
5. Improved overall control and better inventory tracking.
Key zones in the layout design
It is important to identify and organize different zones that will play a specific role in the logistics process. In general, these five distinct zones in the warehouse are essential for proper operation.
1. Loading and unloading areas
Loading and unloading zones are the entry and exit gates of any warehouse. Intelligent design in these areas not only speeds up the flow of goods, but also minimizes waiting times. The implementation of wide access and efficient dock systems facilitates simultaneous loading and unloading, reducing bottlenecks and improving the overall efficiency of the logistics process.
2. Receiving area
The receiving area is the point of entry of products into the warehouse. An optimal design in this area streamlines the inspection and check-in process, allowing for quick integration of products into the inventory. The implementation of technologies such as radio frequency identification (RFID) can improve accuracy and speed in receiving goods, contributing to more efficient inventory management.
3. Storage area
The heart and soul of any warehouse lies in the storage area. A strategic layout here maximizes storage capacity and facilitates product placement and retrieval. The use of vertical storage systems, such as intelligent shelving and racks, optimizes the available space, allowing quick and easy access to stored products. Intelligent sorting and clear labeling contribute to reducing errors and increasing speed in order picking.
Normally, there are two types of storage in the storage area:
Stack storage Stacked storage is storage by placing the load one on top of the other. Only the pallet is the one that supports the structure. Its main advantage is the better use of space, since no unused positions are created. Not all materials can be stored in this way and it must be taken into account that even those goods that can be stored in this way have a maximum stacking height. On the other hand, the great disadvantage of stacked storage is that it does not allow any user to access the load without first dismantling the stack on top of it. This type of stacking is usually used with two main types of cargo:
- High internal resistance cargo, such as bricks, concrete blocks, etc. allow to be stored directly without any risk.
- Cargo in rigid containers, such as cardboard, wooden or plastic boxes, can be stacked in this way without problems, although the strength of the box material must be considered in order to calculate its stacking capacity.
Racking and shelving This is the most common type of storage in logistics warehouses. Racking storage consists of the placement of metal structures formed by properly braced beams. These multi-cell type metallic structures generate hollows where the load units can be deposited. The configuration and arrangement of the cells (or alveoli) can vary to accommodate different needs.
4. Order picking area An efficient picking zone is essential to meet customer demands in a timely manner. This requires a design that minimizes travel distance and facilitates product grouping, which improves picking speed. The implementation of technologies such as warehouse management systems (WMS) and voice picking further streamlines this process, reducing errors and improving accuracy in shipping products.
5. Shipping area
The shipping area is the last stage before products reach their final destinations. Efficient design here ensures smooth coordination between order picking and delivery. The implementation of automatic scanning and labeling systems ensures correct product identification and avoids errors in the loading of transport vehicles.
Personnel or service areas An area of the warehouse that is often relegated to the background is the one destined to the general services of the warehouse itself. We are talking about activities such as administrative management, toilets, changing rooms and machinery loading and other essential elements. The control office should be located in the reception and dispatch area to speed up the input and output processes, which normally pass through this department. If we are talking about changing rooms, toilets and general offices, the most reasonable location a priori is in the vicinity of the control offices. We often see a floor built over the reception and dispatch area to install these facilities. Other key elements in a warehouse layout
During the design of a warehouse layout, there are other elements that also play a fundamental role in the efficiency of logistics management:
- Distribution and space utilization: it is necessary to strategically plan the location of shelves, aisles and work areas to maximize the available space. In addition, it is essential to take into account the correct arrangement of products and the implementation of efficient storage systems.
- Choice of physical elements: pallets and racks. The right choice of pallets, taking into account their resistance and characteristics, as well as the type of racking, considering load capacity and accessibility, contribute to a better organization and use of space.
- Forklift selection: Depending on the layout of the pallets, the type of racking and the goods to be handled, forklifts should be chosen to suit the specific needs of each warehouse. It is important to consider aspects such as load capacity, size, maneuverability and type of dexterity required.
There are many factors that influence the efficiency of the logistics chain, but the layout of the warehouse is perhaps one of the most important, since it is one of the points where the different products or materials come together for distribution.