Warehouse Layout & Zones

Warehouse layout management defines the physical structure of your warehouse including zones, aisles, racks, and bins. Proper layout design optimizes storage capacity and operational efficiency.

Overview

Layout management enables you to:

• Design warehouse floor plans
• Create and manage zones
• Configure bin locations
• Set storage conditions
• Manage capacity allocation
• Optimize item placement

Accessing Layout Management

Navigate to Warehouse → Layout to access layout features.

Understanding Warehouse Structure

Location Hierarchy

Warehouse (Main DC)
├── Zone (Receiving)
│   ├── Dock 1
│   ├── Dock 2
│   └── Staging Area
├── Zone (Storage)
│   ├── Aisle A
│   │   ├── Rack A01
│   │   │   ├── Level 1 (Floor)
│   │   │   │   ├── Bin A01-1-01
│   │   │   │   └── Bin A01-1-02
│   │   │   └── Level 2
│   │   └── Rack A02
│   └── Aisle B
├── Zone (Pick Face)
│   └── Fast-moving items
├── Zone (Packing)
│   ├── Station 1
│   └── Station 2
└── Zone (Shipping)
    └── Staging lanes

Zone Types

Zone	Purpose	Characteristics
Receiving	Inbound processing	Dock access, staging
Quality	Inspection area	Hold until cleared
Bulk Storage	Long-term storage	High density, less access
Pick Face	Active picking	Fast access, replenished
Forward Pick	High-velocity items	Ground level, ergonomic
Packing	Order completion	Workstations, supplies
Staging	Pre-ship holding	Organized by carrier/route
Shipping	Outbound dispatch	Dock access, loading
Returns	Return processing	Inspection, restocking
Hazmat	Dangerous goods	Compliant storage

Bin Types

Type	Description	Use Case
Rack	Standard racking	Pallets, cases
Shelf	Shelving units	Small items, each picks
Floor	Floor storage	Large/heavy items
Bin	Storage bins	Small parts, components
Flow Rack	Gravity flow	FIFO, high velocity
Drive-In	Drive-in racking	High density, LIFO
Cantilever	Long item storage	Pipes, lumber, carpet

Creating Warehouse Layout

Setting Up Warehouses

1. Go to Settings → Warehouse → Locations
2. Click New Warehouse
3. Enter details:

Basic Information

• Code - Unique identifier (e.g., "MAIN-DC")
• Name - Descriptive name
• Address - Physical location
• Type - Distribution center/store/3PL
• Status - Active/Inactive

Operational Settings

• Operating Hours - Work schedule
• Time Zone - Local time zone
• Default Putaway - Storage strategy
• Default Picking - Pick strategy

4. Save warehouse

Creating Zones

1. Go to Warehouse → Layout → Zones
2. Click New Zone
3. Configure zone:

Field	Description
Zone Code	Unique identifier
Zone Name	Descriptive name
Zone Type	Receiving/Storage/etc.
Warehouse	Parent warehouse
Sequence	Processing order
Capacity	Maximum storage

4. Set zone rules
5. Save zone

Creating Bin Locations

1. Go to Warehouse → Layout → Bins
2. Click New Bin or Bulk Create

Single Bin Creation

• Bin Code - Location code
• Zone - Parent zone
• Bin Type - Rack/Shelf/Floor
• Dimensions - L × W × H
• Max Weight - Weight capacity
• Storage Class - Item restrictions

Bulk Bin Creation

Generate bins automatically:

Prefix: A
Aisles: 1-10
Racks: 01-20
Levels: 1-5
Pattern: {Aisle}{Rack}-{Level}
Result: A01-01-1, A01-01-2, ... A10-20-5

How-To Guides

How to Design Warehouse Layout

Planning Considerations

Traffic Flow:

• One-way aisles
• Cross-aisles for shortcuts
• Separate inbound/outbound
• Emergency exits

Storage Efficiency:

• High items = more locations
• Fast movers near shipping
• Heavy items at floor level
• Related items together

Layout Design Steps

1. Analyze Requirements

   • Item characteristics
   • Volume forecasts
   • Pick frequencies
   • Special storage needs

2. Define Zones

   • Receiving and shipping docks
   • Storage areas
   • Picking zones
   • Packing and staging

3. Plan Aisles

   • Main aisles (wider)
   • Cross aisles
   • Pick aisles
   • Equipment clearance

4. Configure Bins

   • Bin sizing
   • Level heights
   • Capacity planning
   • Labeling scheme

How to Create Zones

Zone Configuration

1. Receiving Zone

   Type: Receiving
   Functions: Unloading, inspection, staging
   Equipment: Dock doors, pallet jacks
   Bins: Staging lanes, hold areas

2. Storage Zone

   Type: Bulk Storage
   Functions: Long-term storage
   Equipment: Forklifts, reach trucks
   Bins: Pallet positions, rack locations

3. Pick Zone

   Type: Pick Face
   Functions: Order picking
   Equipment: Carts, RF scanners
   Bins: Shelves, flow racks

4. Pack Zone

   Type: Packing
   Functions: Boxing, labeling
   Equipment: Pack stations, scales
   Bins: Work areas, supply storage

How to Configure Bin Locations

Bin Naming Convention

Recommended format:

[Zone][Aisle][Rack]-[Level]-[Position]
Examples:
A01-01-1  = Zone A, Aisle 01, Rack 01, Level 1
B05-03-2  = Zone B, Aisle 05, Rack 03, Level 2

Bin Attributes

Attribute	Purpose
Dimensions	Fit verification
Weight Limit	Load capacity
Storage Class	Item restrictions
Pick Sequence	Pick path order
Replenish Point	Trigger level
ABC Class	Velocity category

How to Set Storage Conditions

Temperature Zones

Zone	Range	Items
Ambient	15-25°C	General goods
Cool	8-15°C	Some chemicals
Refrigerated	2-8°C	Perishables
Frozen	-18°C or below	Frozen goods

Special Conditions

• Humidity Control - Sensitive items
• Hazmat Storage - Dangerous goods
• Secure Storage - High-value items
• Climate Control - Electronics

How to Manage Capacity

Capacity Planning

Monitor utilization:

• Physical Capacity - Total locations
• Used Capacity - Occupied locations
• Available - Free locations
• Reserved - Pre-allocated

Capacity Alerts

Set thresholds:

• Warning at 80% full
• Critical at 90% full
• Auto-alert warehouse manager
• Trigger expansion planning

How to Implement Slotting

ABC Analysis

Classify items by velocity:

Class	% of SKUs	% of Picks	Placement
A	20%	80%	Prime locations
B	30%	15%	Mid-tier access
C	50%	5%	Bulk storage

Slotting Rules

• A items: Ground level, near packing
• B items: Easy reach, mid-warehouse
• C items: Upper levels, back of warehouse
• Heavy items: Floor level
• Light items: Higher shelves

Re-Slotting

Periodic optimization:

1. Analyze pick data
2. Identify misplaced items
3. Generate move recommendations
4. Execute slot moves
5. Update locations

Advanced Features

Visual Layout Editor

Drag-and-drop design:

• Draw zones
• Place racks
• Define aisles
• Set dimensions
• Print layouts

3D Warehouse View

Interactive visualization:

• Navigate warehouse virtually
• View bin contents
• Check capacity
• Identify locations

Heat Maps

Visual analytics:

• Pick frequency heat map
• Capacity utilization
• Movement patterns
• Problem areas

Barcode/Label Printing

Generate location labels:

• Bin barcodes
• Zone markers
• Aisle signs
• Rack labels

Best Practices

🏗️ Design

• Logical flow patterns
• Adequate aisle width
• Safety clearances
• Future expansion space

📍 Organization

• Consistent naming
• Clear signage
• Regular audits
• Clean locations

📊 Optimization

• Regular velocity analysis
• Seasonal adjustments
• Slotting reviews
• Capacity monitoring

🔒 Safety

• Emergency access
• Fire suppression
• Load limits posted
• Equipment zones

Configuration

Location Settings

Navigate to Settings → Warehouse → Locations:

• Location Format - Naming pattern
• Auto-Sequence - Pick path numbering
• Capacity Tracking - Enable/disable
• Check Digit - Verification

Zone Settings

• Zone Types - Available categories
• Default Rules - Putaway/picking
• Restrictions - Item limitations
• Cross-Zone - Movement rules

Bin Settings

• Bin Types - Rack/Shelf/Floor
• Dimensions - Default sizes
• Weight Limits - Capacity defaults
• Status Codes - Active/Blocked/etc.

Troubleshooting

Common Issues

Bin not found

• Verify bin code correct
• Check zone active
• Review location status
• Search in archive

Capacity exceeded

• Check bin limits
• Review weight capacity
• Verify dimensions
• Audit contents

Item cannot be stored

• Check storage class
• Verify temperature zone
• Review restrictions
• Check hazmat rules

Layout changes not reflecting

• Clear cache
• Refresh view
• Check sync status
• Verify permissions

Next Steps

Learn about Picking Operations to efficiently fulfill orders from your warehouse.