What are the best practices for designing warehouse aisles and zones?

1 Warehouse aisles

Warehouse aisles are the pathways between storage racks or shelves, where workers and equipment move around. The width, length, and orientation of aisles depend on several factors, such as the size and shape of the warehouse, the type and quantity of inventory, the picking method, and the equipment used. When designing warehouse aisles, it is important to consider the right aisle width for your equipment and inventory, which can range from narrow (less than 6 feet) to wide (more than 12 feet). Narrow aisles can save space and increase storage density, but wide aisles can accommodate standard equipment and allow more flexibility. Additionally, it is important to align aisles with the flow of goods and traffic, which can be parallel or perpendicular to the loading docks. Furthermore, optimizing aisle length and layout is essential, as aisle length can be determined by the number of storage bays or the warehouse dimensions. Aisle layout can be straight, curved, or angled, depending on the warehouse shape and the inventory layout. All of these best practices can help improve access and visibility, reduce travel distance, and simplify navigation and picking.

2 Warehouse zones

Warehouse zones are the areas where inventory is stored, sorted, or processed, according to its characteristics, demand, or function. The number, size, and location of zones depend on several factors, such as the type and variety of inventory, the order frequency and volume, the picking method, and the warehouse layout. To design warehouse zones that suit your inventory management needs and goals, it is best to group inventory by similar attributes or requirements, demand or popularity, and function or process. For example, bulky, heavy, or palletized items can be stored in floor or lower-level zones, while small, light, or loose items can be stored in shelf or upper-level zones. Additionally, high-demand or fast-moving items can be stored in zones that are close to the loading docks or the picking area, while low-demand or slow-moving items can be stored in zones that are farther away or in remote locations. Furthermore, cross-docking items can be stored in zones that are near the loading docks or the outbound area, while kitting or assembly items can be stored in zones that are near the workstations or the packing area. However, you should also consider other factors, such as your budget, your available space, your warehouse operations, and your future growth. You may need to test, evaluate, and adjust your warehouse layout periodically, to ensure that it remains optimal and effective.