There are six distinct logical steps leading to an optimum warehouse design. The balance between these phases is dependent on circumstances, but all play a role to some extent. Focused Logistics has extensive experience in each activity, and a number of proprietary tools to support the analysis.

Steps:

  1. Operational profile
    The purpose of profiling is to determine the warehouse design requirements, based on accurate data and validated assumptions. This provides clear and agreed design inputs.
  2. Storage & pick methods
    Calculate the optimum mix of storage methods and pick solutions, to balance space usage and productivity. The outputs are a summary of physical warehouse design requirements.
  3. Warehouse size
    In order to size the operations, the warehouse footprint is calculated accommodating storage and throughput volumes. This is influenced by a number of variables including; building height, storage units, rack configuration, product flows and timings. Multiple configurations can be quantitatively compared to find the preferred layout options.
  4. Resource requirements
    Our proprietary model calculates the hourly MHE and staffing requirements at warehouse task level over a defined simulation period. Tasks are grouped to manage requirements at shift or team level. Operational scenarios can be evaluated in detail. The timed nature of the model provides insights in peak requirements and constraints. The model provides accurate input to cost modelling.
  5. Warehouse layout
    Detailed layouts are created to fit existing facilities or new builds. Alternative layout scenarios can be drawn up in 3D renders to compare options and to communicate design features.
    The layout is optimised to maximise productivity, support peak throughput and allow flexibility. Best practise safety concepts are applied by our consultants.
  6. Business case
    This is the ultimate test of the viability of a warehouse design or improvement initiative. It supports the case for change as part of the approval process.
    The budget model costs alternative warehouse scenarios and is used in conjunction with a summary of non-quantifiable factors to identify the preferred design option. The model compares both capital and annual costs of warehouse solutions.

The above methodology can be applied to operations of any size or complexity. Industry specific characteristics are accounted for throughout all steps. To find out more about our experience, please contact Eddy de Jong

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