An optimized warehouse starts with properly designed storage racks aligned to space, inventory profiles and operational workflows. By strategically positioning purpose-built racking systems, businesses can maximize usable cubic density, boost productivity and flexibility as inventory volumes grow and evolve. This article explores professional racking layout planning approaches.
Matching Designs to Material Types
Achieving efficient warehouse racking layouts requires tailoring storage solutions to the types of inventory and materials being handled:
Pallets of Boxes/Cartons – Selective pallet racking provides adjustable shelves and bays for mixed boxed inventory. Drive-in racks concentrate high volumes of same-size SKU pallets.
Bulky and Irregular Items – Free-standing cantilever racks with extended arm supports fit long items like pipes, beams and lumber without wasting in-rack space. Wide openings allow easy access.
Perishable Goods – Incorporate first-in-first-out flow rack designs with integrated gravity roller or cart conveyance to smoothly move perishable pallets, facilitating stock rotation and preventing spoilage.
Automotive Parts – Multi-level mezzanines with customized shelving ensure small items remain visible and accessible. Flow racks also effectively organize automotive components.
Hanging Garments – Install specialized cantilever racking with extended arms featuring integrated hanging bars and hooks for efficiently storing hanging textiles using warehouse height.
Gather Key Facility and Inventory Data
Initiate layout planning by quantifying all physical warehouse dimensions, restrictions and current/expected inventory details. Exact measurements of total and zoned ceiling heights and obstacle items like columns and utilities enable ideal rack height configurations. Details on all pallet SKUs, dimensions, turnover and weight capacities drive rack type selections.
Map Ideal Process Flows First
Consider desired picking, loading, replenishment and other material workflow routing independent initially from fixed facility constraints. This exercise highlights ideal efficiency milestones if building storage flows from scratch. Then overlay limitations progressively to refine the dream workflow balancing perfection and practicality through customized racking.
Blend Racking Types to Maximize Density
Mix compatible racking types like selective, drive-through and cantilever based on inventory profiles and access demands per zone rather than homogenizing storage styles. Specialized area-focused designs align better to operational needs than conformity. Carefully evaluate adjacency planning for racking and inventory transitions too.
Simulate and Adjust Repeatedly
Leverage 2D and 3D warehouse modeling software visualizing various layout proposals incorporating expected volumes and processes. Refine iteratively until maximizing stated density, management and turnover efficiency goals. Simple adjustments often cascade optimizations. Future flexibility for scaling or use modifications should remain a priority.
Bring In Racking Design Authorities
Storage pros like Prince Steel apply rack layout design and simulation best practices honed over decades of complex installs. Our teams evaluate custom needs, model solutions in software plus physically onsite, identify optimizations opportunities and handle professional fabrication plus installation. Augment your warehouse ROI through expert engagement.
Contact us today at 480-405-0940 for your free evaluation!