WAREHOUSE WMS CAPACITY PLANNING CHECKLIST

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--- DEMAND FORECASTING ACCURACY ---
[ ] Forecast Accuracy Rate (%)
[ ] Description of Forecasting Methodology
[ ] Software Used for Forecasting (Excel, Dedicated Forecasting Software, Other)
[ ] Average Forecast Error (Units)
[ ] Date of Last Forecast Review
[ ] Data Sources Used for Forecasting (Historical Sales Data, Market Trends, Promotional Plans, Economic Indicators)

--- STORAGE SPACE UTILIZATION ---
[ ] Overall Rack Space Utilization (%)
[ ] Average Pallet Density per Rack Level
[ ] Racking Type in Use (Selective Pallet Racking, Drive-In Racking, Flow Racking, Pallet Shuttle, Other)
[ ] Description of Current Storage Layout
[ ] Percentage of Empty Rack Locations
[ ] Areas of Low Utilization (Select all that apply) (Top Rack Levels, Back of Warehouse, Specific Aisles, Seasonal Storage Areas, None)

--- RECEIVING CAPACITY ASSESSMENT ---
[ ] Number of Dock Doors
[ ] Average Daily Receipts (Units)
[ ] Peak Daily Receipts (Units)
[ ] Receiving Labor Available (Full-Time Equivalents)
[ ] Current Receiving Process (Manual, Semi-Automated, Fully Automated)
[ ] Describe any current bottlenecks in the receiving process
[ ] Date of last Receiving Capacity Review

--- PUTAWAY RESOURCE EVALUATION ---
[ ] Current Number of Putaway Laborers
[ ] Average Putaway Rate (Units/Laborer/Hour)
[ ] Primary Putaway Equipment (Forklift, Pallet Jack, Automated Guided Vehicle (AGV), Manual)
[ ] Number of Available Forklifts/Pallet Jacks
[ ] Description of Current Putaway Process
[ ] Current Putaway Method (Directed, Random, Zone, FIFO)
[ ] Average Time to Complete Putaway (Minutes)

--- PICKING & PACKING CAPACITY ---
[ ] Average Orders Processed Per Hour
[ ] Peak Hour Order Volume
[ ] Number of Picking Stations
[ ] Average Pick Time Per Order (minutes)
[ ] Number of Packing Stations
[ ] Average Packing Time Per Order (minutes)
[ ] Picking Method (Zone Picking, Wave Picking, Batch Picking, Discrete Picking)
[ ] Notes on Bottlenecks or Challenges

--- SHIPPING CAPACITY & DOCK SCHEDULING ---
[ ] Number of Dock Doors Available
[ ] Average Dock Door Utilization Rate (%)
[ ] Maximum Number of Shipments Per Day
[ ] Average Dock Door Turnaround Time (Minutes)
[ ] Earliest Shipping Start Time
[ ] Latest Shipping End Time
[ ] Dock Scheduling Method (First Come, First Served, Priority Scheduling, Appointment-Based)

--- LABOR AVAILABILITY & SKILL SETS ---
[ ] Current Number of Warehouse Associates
[ ] Projected Number of Associates Needed (Next 6 Months)
[ ] Dominant Skill Set Deficiency (Forklift Certification, Picking & Packing, WMS Software Proficiency, Receiving and Inspection, General Labor)
[ ] Training Programs Currently Offered (Forklift Certification, WMS Software Training, Safety Procedures, Picking Optimization)
[ ] Date of Last Workforce Skills Assessment
[ ] Description of Current Labor Challenges

--- EQUIPMENT MAINTENANCE & RELIABILITY ---
[ ] Last Preventative Maintenance Date
[ ] Total Equipment Downtime (Hours) - Last Month
[ ] Description of Recent Equipment Issues/Repairs
[ ] Equipment Condition Rating (1-5) (1 - Critical, 2 - Poor, 3 - Fair, 4 - Good, 5 - Excellent)
[ ] Next Scheduled Maintenance Date
[ ] Number of Critical Equipment Failures Last Quarter

--- AUTOMATION POTENTIAL ASSESSMENT ---
[ ] Describe current manual processes suitable for automation.
[ ] Which automation technologies are being considered? (Automated Guided Vehicles (AGVs), Automated Storage and Retrieval Systems (AS/RS), Robotics (Pick and Place), Conveyor Systems, Voice Picking Systems, Automated Labeling Systems)
[ ] Estimated ROI (Return on Investment) for automation implementation.
[ ] Estimated cost of automation implementation.
[ ] Target implementation date for automation.
[ ] Level of automation being considered (e.g., Partial, Full) (Partial Automation, Full Automation)

--- PEAK SEASON PLANNING & SCALABILITY ---
[ ] Projected Peak Season Order Volume Increase (%)
[ ] Additional Labor Needed (Full-Time Equivalents)
[ ] Extra Dock Doors Required (Number)
[ ] Start Date of Peak Season Prep (YYYY-MM-DD)
[ ] End Date of Peak Season (YYYY-MM-DD)
[ ] Peak Season Strategy (Temporary Staffing, Overtime, Extended Hours, Contracted Logistics)
[ ] Potential Bottlenecks During Peak Season (Receiving, Putaway, Picking, Packing, Shipping, Order Management)

--- WAREHOUSE LAYOUT OPTIMIZATION ---
[ ] Describe current warehouse layout challenges.
[ ] Current average travel distance per pick (feet).
[ ] Primary layout type (e.g., flow-through, U-shaped, I-shaped). (Flow-Through, U-Shaped, I-Shaped, Other)
[ ] Which areas are experiencing bottlenecks? (Receiving, Storage, Picking, Packing, Shipping)
[ ] Describe proposed layout changes and rationale.
[ ] Estimated reduction in travel distance with new layout (%).

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