2022年仓库布局设计规划:步骤+Examples

To know your current space utilization, you need to calculate your total warehouse size and potential storage area size. Knowing these metrics helps establish limits on how you store products and lets you know when your warehouse is at full capacity.

Once you have calculated your storage space, the next step would be to plot your workspace and plan for equipment.

• Step 1: Identify your key units.

These are the things that take up most of your space and/or are the center of your production zones. A business’s key warehouse units, such as manufacturing equipment or workstations, will vary based on the primary goals of the facility.

Whatever your key units are, you need to identify and place these elements on your planfirst. Storage spaces, while equally important, aresecondaryin your plan—their locations are dependent on where you position your equipment.

For example, if you run anecommerce companythat stocks and ships goods, your key units would be pallet racks and metal shelving. You can see what this layout looks like in the image below.

• Step 2: Allow sufficient space so that any equipment used—from hand trucks to forklifts—can navigate the warehouse aisles easily.

Again, this will vary greatly depending on the products you sell, as different types of products require different handling equipment—which, in turn, affects your aisle spacing. For example, a forklift will need more space than a pallet jack.

After addressing primary units like equipment, stock shelving, and assembly stations, the next step is thinking about how workers, materials, and goods move in and around your key elements. You also need to consider the space necessary for your production work to safely occur.

Safety needs to be a prime consideration in all warehouses—though it may be more complex in manufacturing, where movement occurs around equipment. The Occupational Safety and Health Administration (OSHA) offers detailed publications that you should review inplanning your warehouse safety initiatives.

For example, a stock and ship operation’s primary work area is the aisle space between shelving units, as shown below. This is where you or your employees need adequate space to stock received goods and pick items for orders. You’ll also need to allocate workspace for employees to move goods into, around, and out of the production zones—which are your packing, shipping, and receiving areas.

Assembly operations often combine the spatial needs of manufacturing and stock & ship. In these cases, assembly stations and related equipment make up the heart of your production zone. These can include workbenches or specialized stations, plus bins for parts and finished goods. Like manufacturing, you need to allocate ample production space around these areas. Then, like stock and ship, you need to reserve space to efficiently package finished goods.

Storage is another key factor to consider in your layout. In fact, for pack and ship (and some assembly operations), efficient arrangement of storage areas is likely your prime concern.

Forklifts require ample space to navigate storage units.

Best for:Midweight to heavyweight storage needs like boxed stock, work materials, and finished goods.

Expect to pay between $120–$350 per set for new, heavy-duty warehouse racking.

Pallet racks are available in various sizes and are designed to store pallets of goods. They’re also used for stocking all sorts of products and materials, large and small.

These are assembled using end units calleduprights, adjustable crossbars calledrails, and heavy-duty particleboard or metal wire grid shelves calleddecks. You can assemble many shelves or just a few on each unit.

Pallet rackscanbe freestanding, though they’re designed to interconnect for long shelving runs. When used this way, it’s the most cost-effective shelving solution for large warehouse storage areas. If you have storage space of 1,000 square feet (around 20 x 50 feet) or more, two long rows of pallet racks can provide ample storage at a reasonable cost.

Best for:Light to midweight storage in smaller warehouses, storage units, and garages

You can expect to pay $75–$200 for a new HD shelving unit. (Source: Alibaba)

重型(HD)货架托盘货架的婴儿brother. The name is a bit deceiving, as pallet racks generally hold more weight than HD shelving, but HD shelving is a cost-effective solution in many warehouse designs.

Pay attention to the weight ratings on the shelves you purchase; for safety reasons, it’s important to adhere to weight stipulations assigned by the shelving unit’s manufacturer. If you just need a few units, you can buy these shelves anywhere shelving hardware is sold, including Home Depot, Amazon, and Lowe’s.

Best for:Garages, small retail storerooms, and residential storage areas like utility or craft rooms (small businesses or one-man businesses, hobby or side hustle)

Light-duty (LD) shelving is an inexpensive choice for small warehouse spaces and storage units. A notable advantage of LD shelving is that most units come with five or six adjustable shelves, which gives you useful versatility if you’re storing various items of different dimensions. Light-duty shelving also works well with stacked parts bins (discussed below) for stocking small items and assembly parts.

Take note, though, that if you want to maximize the height of your warehouse for extra storage space, you won’t be able to do that with LD shelving as these units are usually only 6’ to 7’ high.

Best for:Specific storage for oversized items

Cantilever rack prices are available by custom quote. (Source: BicroSelect)

Cantilever racks can handle your pipe, lumber, panels, and oversize material storage needs. Sizes and costs vary by need and type of material stored, so you’ll need to contact a used warehouse dealer or online vendors—like Alibaba or Shelving.com—to get a quote for your warehouse.

Best for:Storing and transporting loose materials, often involved in assembly operations

Expect to pay $100–$200 for the caliber of box illustrated in the image. (Source: Alibaba)

Metal and heavy-weight plastic storage boxes, hoppers, and barrels are common in manufacturing and assembly operations. They are receptacles used to store, transport, and dump materials.

Many businesses move these on pallets using pallet jacks, but some bins and hoppers are wheeled. You can purchase these in various sizes and materials that are capable of holding even heavy items.

Best for:Small, loose assembly parts for packing

Small parts and assembly bins usually cost $1–$10 each. (Source: Alibaba)

These handy, stackable bins are ideal for storing small items for all sorts of needs—including materials for manufacturing, parts for assembly, and small goods for pack and ship. Plus, their easy-access design makes them an efficient alternative to stocking small goods in closed boxes, and they can be easily color-coded.

In the ecommerce pick-pack-and-ship warehouse layout below, notice where the aisles (A) for product storage are placed.

You can see how various elements were brought into the warehouse floor plan to facilitate efficiency in this warehouse model. The busiest production zone—the packing area—is centrally located between stock shelves, with two aisles that directly feed into it.

This warehouse layout allows staff to quickly access or “pick” the product on either side of the packing tables. Plus, each employee is assigned a specific section to pick and maintain, which keeps them from bumping into each other. All of this culminates in an effective and efficient traffic flow.

Stock storage areas are maximized by using a 12’-tall pallet rack that allows ample overstock space on upper shelves—out of the path of daily workflows. Hand-carried bins and small carts are used for restocking and order picking tasks among the shelves.

Four-foot aisle widths suit this warehouse’s box- and cart-moving needs. Ample space is left for pallet movement along the central aisles since the warehouse receives and ships palletized freight.

Shelving is not used against the end walls. Instead, this warehouse runs 2’-deep shelving along the perimeter for smaller items. This enables pickers to move from aisle to aisle without backtracking and pick small items along the way as needed.

Packing and shipping is the primary goal of this example ecommerce operation, so ample space is dedicated to these tasks.

在中央包装区(B)、仓库out includes a mix of 8’ and 6’ utility tables that can be moved and rearranged as packing needs dictate. This lets warehouse employees handle daily parcel packing with room to spare, easily accommodates holiday volumes, and allows staff to pack pallets for large freight orders.

As a pack-and-ship operation, this ecommerce warehouse storesshipping boxes and packing materialsin easy reach of the packing tables. Once parcels are packed, they are quickly moved to the nearby shipping station table for weighing, sealing, and labeling.If you plan on shipping daily, allocating space for a dedicated shipping station is a real time-saver.

Order fulfillment and shippingcan be a bit tricky. If you’re new to in-house fulfillment, research existing operations to take a look at how others perform fulfillment and shipping cost-effectively. Doing this type of homework can save money and hours of frustration.

Ample room is available in this model for shipping and receiving, thanks to the large overhead doors (C). As a pack-and-ship ecommerce operation, this company receives numerous freight and parcel stock shipments daily.

Allowing room to store received stock prior to unpacking is essential. Plus, it’s helpful to keep receivables separate from daily outbound parcels to prevent confusion and carrier pick-up mistakes.

This warehouse uses two rolling staircases to safely store and retrieve large numbers of lightweight overstock boxes from its 12’ shelves.

If you plan to use high shelves in your warehouse, be sure to develop a way to securely access items that are overhead. In this example, rolling staircases work just fine. In other warehouses, heavier equipment such as forklifts are needed to transport and access items stored overhead.

Since the rolling staircases take up warehouse floor space, their storage must be considered in the warehouse layout. The spaces marked (D) near the receiving and shipping areas are used to store the rolling staircases.

Rolling ladders, moving conveyors, and pallet jacks are also things to keep in mind when planning your warehouse layout. If you don’t currently use them but think you might need to down the line, allocate warehouse space for these items now. Once you get your heavy equipment situated or rows of shelving securely installed, you don’t want to move them to make space for pallet jacks and other large items you had not considered.