Optimize Your Warehouse Layout in 5 Easy Steps

We have customers who have a brand-new warehouse that are looking to layout their warehouses efficiently as well as warehouses that have had the same layout for decades. Is your shipping operation small, medium, or large? In any case, consider the following layout strategies that can help maximize your shipping and business operations:

  1. How Wide Are Your Aisles?

How wide are your aisles? The general rule of thumb has always been to set your aisles 11 feet apart for forklift operations, but it really depends on what forklifts you have in your warehouse. There are a variety of forklifts with different styles so you will have to take a look at what works best for your operations. Did you know that there are newer generation forklifts that will allow you to cut your aisle widths down to 5 feet?


  1. Review Product Velocity

How are you organizing and arranging your products in your warehouse? A common misstep we have found is to group similar products together. Instead of putting similar products next to each other, you may want to try grouping your products with the top movers as close to your shipping lanes to reduce travel time and pack merchandise faster.

  1. Travel Time/Distance

Number 2 and 3 go hand-in-hand. Whether your warehouse is small or large, there’s a misconception that the more space you have, the better storage you will have. Do you ever notice how far each employee travels to pick items by foot and by forklift? The key is to reduce travel time which will increase productivity and get your orders out as efficiently as possible. All that walking not only wastes time, but it also overworks your employee unnecessarily.

  1. Dusty Items and Honeycombs

Are there items collecting dust in your warehouse? Consider only keeping items that you sell on your shelves regularly versus items you just want to keep on-hand that are gathering dust.  It would be less costly to take out the outdated and unsold items than to keep it on the shelves gathering dust. Another thing to look for in your warehouse are called “honeycombs”.  If you have any gaps behind, above, or alongside products, then you’re not using your shelves efficiently. For smaller items, consider using bins or smaller shelves to maximize the space that is wasted.


  1. Packing Line – Shipping

How efficient is your shipping operation? For smaller shippers, do you just grab a big roll of bubble wrap whenever you need to pack boxes? How streamlined is your shipping line?

AirSaver has many configurations that will work with any type of shipping operation from large to small. With our standalone machine and accessories like our collection basket to overhead delivery system, you won’t need to worry about storage space.

What Now?

In conclusion, taking a look at the 4 items that we mentioned above can help your warehouse operation find up to 18% more space. Relocating top movers and removing slow movers will improve your company’s bottom line and increase space in your warehouse as well.  Lastly, don’t forget about your packing stations. Consider saving space and money with, AirSaver.

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