WAREHOUSE LAYOUT OPTIMIZATION REVIEW

Created by ChecklistGuro (https://checklistguro.com)


--- INITIAL ASSESSMENT & DATA GATHERING ---
[ ] Date of Last Layout Review
[ ] Current Warehouse Square Footage (sq ft)
[ ] Brief Description of Current Warehouse Operations
[ ] Average Daily Orders Processed
[ ] Current Warehouse Management System (WMS) Used (if any) (None, SAP, Oracle WMS, Manhattan Associates, JDA/Blue Yonder, Other - Specify in LONG_TEXT)
[ ] Existing Warehouse Layout Map (if available)
[ ] Number of Full-Time Warehouse Employees
[ ] Summary of Key Operational Challenges (e.g., bottlenecks, safety concerns)

--- RECEIVING & PUTAWAY OPTIMIZATION ---
[ ] Average Receiving Lead Time (Days)
[ ] Receiving Dock Capacity (Pallets/Hour)
[ ] Receiving Dock Scheduling System? (Yes, No, Partial (Some Carriers))
[ ] Receiving Damage Causes? (Forklift Damage, Improper Packaging, Poor Dock Lighting, Employee Error, Other)
[ ] Putaway Method? (Random, Directed, Zone-Based)
[ ] Describe the current process for assigning storage locations during putaway.
[ ] Percentage of Items Requiring Special Handling During Putaway

--- STORAGE LAYOUT & SLOTTING ---
[ ] Average Travel Distance per Pick (meters)
[ ] Slotting Strategy (e.g., Velocity-Based, Random, ABC) (Velocity-Based, Random, ABC Analysis, Cube-Based, Other (Specify))
[ ] Description of Current Slotting Rules & Criteria
[ ] Factors Considered in Slotting Decisions (select all that apply) (Product Velocity, Product Size/Dimensions, Product Weight, Product Compatibility, Product Storage Requirements (Temperature, Humidity), Pick Frequency, Ease of Access)
[ ] Percentage of Products in Ideal Slot Locations
[ ] Describe any issues related to product accessibility or congestion in storage areas
[ ] Type of Racking System Used (Pallet Racking, Selective Racking, Drive-In Racking, Flow Racking, Mezzanine, Other (Specify))
[ ] Aisle Width (meters)

--- PICKING & PACKING OPTIMIZATION ---
[ ] Average Picking Distance (meters)
[ ] Average Order Size (number of items)
[ ] Picking Method Used (Zone Picking, Batch Picking, Wave Picking, Discrete Picking)
[ ] Order Picking Equipment Used (Pick to Light, Pick to Voice, RF Scanners, Manual Picking)
[ ] Description of Current Packing Process
[ ] Average Packing Time per Order (minutes)
[ ] Packing Material Type (Cardboard Boxes, Poly Bags, Envelopes, Custom Packaging)
[ ] Observed Bottlenecks in Picking/Packing

--- SHIPPING & STAGING ---
[ ] Number of Loading Docks
[ ] Average Dock Utilization Rate (%)
[ ] Staging Area Layout (e.g., FIFO, LIFO, Random) (FIFO (First-In, First-Out), LIFO (Last-In, First-Out), Random)
[ ] Average Staging Time (minutes)
[ ] Description of Current Shipping Process
[ ] Type of Shipping Carrier(s) Used (UPS, FedEx, USPS, LTL (Less-than-Truckload), Private Fleet)
[ ] Location of Staging Area
[ ] Observed Bottlenecks or Issues in Shipping/Staging

--- MATERIAL FLOW & CONGESTION POINTS ---
[ ] Identify Primary Material Flow Paths
[ ] Describe Observed Congestion Points
[ ] Average Travel Distance per Pick (Estimate)
[ ] Types of Material Handling Equipment Used (Select all that apply) (Forklift, Pallet Jack, AGV, Conveyor System, Manual Cart)
[ ] Document Any Bottlenecks Related to Inbound/Outbound Flow
[ ] Peak Hour Processing Time (in minutes)
[ ] Type of Material Flow Most Frequently Bottlenecked (Receiving, Storage, Picking, Packing, Shipping)
[ ] Date of Last Material Flow Observation

--- SAFETY & ERGONOMICS ---
[ ] Adequate Aisle Width (Feet)
[ ] Minimum Safe Distance Between Racks (Feet)
[ ] Floor Surface Condition (Slip Resistance) (Excellent, Good, Fair, Poor)
[ ] Potential Ergonomic Hazards Observed (Check all that apply) (Repetitive Lifting, Awkward Postures, Excessive Reaching, Prolonged Standing, Poor Lighting, None Observed)
[ ] Detailed Description of Any Safety Concerns
[ ] Emergency Exit Visibility and Accessibility (Excellent, Good, Fair, Poor)
[ ] Supporting Photos/Videos of Safety Concerns

--- SPACE UTILIZATION & DENSITY ---
[ ] Current Vertical Space Utilization (%)
[ ] Average Aisle Width (feet)
[ ] Racking Type(s) Currently Used (Pallet Racking, Shelving, Mezzanine, Drive-In, Flow Racking, Other)
[ ] Potential Space-Saving Strategies Considered (Narrower Aisle Widths, Higher Racking, Mezzanine Levels, Automated Storage & Retrieval Systems (AS/RS), Mobile Racking, Vertical Lift Modules (VLMs), Other)
[ ] Describe current challenges related to space utilization
[ ] Potential Increase in Storage Density (%), with proposed changes
[ ] Upload a current warehouse layout diagram
[ ] Type of Storage Primarily Used for Fast-Moving Items (Pallet Racking, Shelving, Flow Racking, Pick Modules, Other)

--- TECHNOLOGY INTEGRATION ---
[ ] Current WMS Version
[ ] Describe Current WMS Functionality & Integration Points
[ ] AGV/Automation Currently in Use? (Yes, No, Planned)
[ ] Existing Warehouse Layout Maps/CAD Drawings
[ ] Which technologies are considered for future implementation? (Automated Storage and Retrieval System (AS/RS), Warehouse Control System (WCS), Radio Frequency Identification (RFID), Voice Picking, Robotics (e.g., Palletizing, Sorting), None)
[ ] Describe current integration between WMS and other systems (ERP, TMS)
[ ] Number of RFID readers currently deployed (if any)
[ ] Is data analytics currently used to optimize warehouse layout? (Yes, No, Planning to implement)

--- FUTURE-PROOFING & SCALABILITY ---
[ ] Projected Annual Growth Rate (Units/SKUs)
[ ] Current Warehouse Capacity Utilization (%)
[ ] Anticipated Peak Season Volume Increase (%)
[ ] Describe planned product line expansions (new SKUs)
[ ] Potential for automation (AGVs, conveyors)? (No planned automation, Limited automation (specific areas), Significant automation planned)
[ ] Potential future changes to business model (select all that apply) (Increased e-commerce fulfillment, Expanded B2B distribution, Shift in product mix (higher/lower volume) , New Geographic Markets, No significant changes anticipated)
[ ] Date of next major business plan review (impacts warehouse strategy)
[ ] Potential locations for expansion if current warehouse is insufficient.

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