Types of warehouse layout

Answer 1

• #1 - large scale drug warehouse with very narrow aisle pallet storage and vertical carousels for small items. Designed to hold as much product as possible in an area where space is VERY expensive.

• #2 - Cross dock layout where pre-picked and stretch wrapped pallets from a local supplier of bulky seasonal items came in the night before, and were then shipped to the chains stores in their own trucks the next day. Picked pallets of product and cartons received and sorted directly to outgoing store lanes (another form of cross docking) were all accumulated in dedicated store lanes for cross dock shipping with little handling or order picking being required.

• #3 - Giant cosmetics company with a full flow rack pick to light system at the back wall of the building (so the conveyor did not bisect the building) and with a large pallet replenishment area behind the rack (and at right angle s to the flow rack and truck doors for ease of access.) Note the very large packing area after the pick area where picked cartons (in totes for ease of conveyor handling) came in in one level and the sealed cartons left on another level directly to the waiting UPS trailers.

• #4 - Seasonal sporting goods and clothing slotted by "sport" as well as "season" and "year round HUB" areas Picking walk time was minimized and product did not have to be moved when it was "off" season. Picking was with batch picking cart.

• #5 - Example of a pallet and broken case ABC pick areasorted by product size and movement. Broken case picking was done from shelving in the bottom level of the pallet rack with pallet storage overhead to insure full use of warehouse cube. Small quantity picking was by case and batch picking with a multi-order picking cart.

• #6 - Large scale JIT furniture parts warehouse located near the main office furniture assembly operation. Product families were placed together (by color in the drawing) for speed of picking. There were truck load deliveries between the buildings every 2 hours or so over a two shift operation.

• #7 - Design to integrate two new companies products into an addition to an existing warehouse. Note use of ABC pick areas for both of the new companies. This layout used batch picking carts for picking and conveyor to transport small shipments (UPS) from the existing warehouse section.

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