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warehouse layout and material flow
Multiload Pallet Moves
When feasible, pallet handling vehicles should carry at least two pallets per move. In the video clip a sit down counterbalance forklift operator is moving two pallets at a time from shipping staging to an outbound truck. Some pallet handling vehicles can handle as many as four pallets per move.
Wide, Clean, Clear Main Aisles
Honda's parts DCs are filled with best practices. Here, wide, clean, and clear main aisles permit safe and efficient inter-aisle movements.
Unobstructed Aisles
One of the dangers of over occupying a warehouse is the inclination to clutter aisles with staged material. The clutter hampers productivity and safety.
Optimal Column Spacing
Warehouse column spacing should maximize storage density and should not obstruct the movement of operators or equipment.
Smart Walls
Wall space should be wisely utilized. In this case push back rack is placed up against the exterior walls since push back racks do not require back side access. American Cancer Society, Atlanta, Georgia, USA
Logical Location Numbering
All locations should be numbered in a logical way, for example Building then Aisle within Building then Row within Aisle then Bay within Row then Level within Bay.
Vertical Staging
Floor level pallet staging is typical. Vertical staging of inbound and outbound pallets is an overlooked means of improving building cube utilization.
Expansion Plans
Any warehouse or DC should be planned with the future in mind - vertically and horizontally and in multiple directions.
Natural Lighting
Natural lighting is often overlooked as a resource to lift employee morale, improve immune response, and increase productivity and accuracy.
Center Aisle Lighting
As simple as the concept may seem; it is many times overlooked to make sure that aisle center ways are well lit.
Over Dock Offices
The efficient use of building cube and cube capacity is one of the most important principles in warehouse layout. The building clear height over docks is rarely well utilized when it could be used for office space, over-dock storage, or over-dock staging.
Sky Lights
Previously mentioned, the use of natural lighting in warehouses not only improves safety, but also improves the mental, emotional, and physical safety of warehouse workers.
Oversight
Another very simple warehouse layout principle is the principle of "oversight"; simply providing warehouse leadership with easy and clear sight lines for warehouse operations.
Clear Delineations
Markings and signage demarking aisle identifiers, dock door numbers, staging lanes, and travel aisles should be well maintained, logical, and in color contrast sufficient to call attention to themselves.
Warehouse CAD
The current and future state of warehouse layouts should be specified in 2D and preferably 3D CAD drawings.
Optimal Building Dimensions
Every warehouse as an optimal length, width, and height for its mission. However, RightChain Research has found that in general, an aspect ratio of building length to depth of 1.5 helps to maximize storage density and minimize material handling costs.
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