How to Lay Out a Warehouse or Distribution Center

Wednesday–Friday • September 23–25, 2009

Classes begin at 8 a.m. each day. Classes end at 5 p.m. on the first two days, and at 3:30 p.m. on the final day.

Welcome and introduction
- Typical approaches to layout planning
- Three fundamentals of layout planning
Case Exercise in Layout Planning
- A six-step simplified planning procedure
- Relationship charts and diagrams
- Hands-on case exercise in warehouse layout
Systematic Layout Planning (SLP)
- The four phases of every layout project
- Systematic planning procedures
- Gathering and projecting key input data

Profiling and Inventory Analysis
- Activity and order profiles
- Inventory profiles
- Zoning and picking methods
- Matching your methods to inventory levels and flows
- Storage capacity calculations
Handling and Storing Equipment
- Unit load handling and storage
- Case and item picking and storage
- Simple and complex equipment
Case Exercises in Methods Selection
- Discussion problems on storage, handling, and order-picking

Classical Layouts and Flow Patterns
- Commodity, activity, and other storage zones
- Basic flow patterns and their benefits
- Charting your operations
- Defining your activity areas
Flow of Materials Analysis
- Ways to measure and visualize material flow
- The quantified flow diagram
- Guided application in flow analysis
- Combining flow and other-than-flow relationships
Estimating Space Requirements
- Five ways to establish space requirements
- Short-range and longer-range space projections
- Case exercises in estimating space requirements
- Balancing space required to space available

Facilities Planning Issues
- Adjusting for physical features of the facility
- The impact of utilities, lighting, HVAC, and other specialized requirements
- Rack and aisle orientations
Case Exercise in Warehouse Layout and Materials Handling
- Team exercise to improve an existing layout
- Rearrange to reduce material handling effort
Case Exercise Continues
- Layout considerations other than material flow

Evaluation of Alternative Plans
- Costs and intangibles
- How to select the best overall layout
Detailed Layouts
- Rack storage areas
- Shelving arrangements and slotting
- Dock areas
- Application of SLP to equipment layout
Case Problem in Distribution Center Planning
- Application of techniques from days 1 and 2 to a distribution center expansion
- Organizing the project
- Developing a preliminary arrangement
- Integrating storage and handling methods

Case Problem Continues
- Improving the preliminary plan
- Responding to changing and unforeseen requirements
Organizing Your Layout Project
- Recap of phases, steps, and planning documents
- Working forms and templates for your next project
- What top management wants to know

We are no longer accepting registrations for this program.
Thank you for your interest.