Optimising Warehouse Layouts for Maximum Efficiency: Strategies for Success
2025-07-17
By Rina Redelinghuys, Customer Services Executive, Cquential, part of the Argility Technology Group
In today's fast-paced and competitive business environment, warehouses play a critical role in the supply chain, acting as the primary storage and distribution centre. An optimised warehouse layout is critical for improving operational efficiency, reducing costs and maximising productivity.
One of the biggest mistakes warehouses make today is failing to use their vertical space effectively. Bad shelving and lack of utilising mezzanine level(s), results in wasted storage capacity and reduced ability to hold stock.
By addressing the fairly typical mistakes outlined below, warehouses can change layouts to achieve improved productivity, efficiency and safety, which will help in saving costs, boost customer satisfaction, and give them that competitive advantage.
Aisles and travel routes that are poorly designed:
- Aisles that are too narrow or full: Insufficient aisle width or badly planned travel routes -defined as the optimised picking route an operator follows - can result in reduced productivity, longer travel times, and safety risks.
- Bottlenecks, accidents, and congestion can literally bring a warehouse to a complete halt when space utilisation, or traffic flow, is poorly controlled.
Insufficient Inventory Control and Storage
- Ineffective slotting: This can be due to poorly optimised storage locations, leading to increased travel times, reduced productivity, and inaccurate inventory levels.
- By default, inventory should be grouped by type (category), size, or movement rate (quick movers vs. slow movers) to avoid errors, damages and unhappy customers.
Lack of Flexibility and Scalability
- Warehouses sometimes fail to plan for expansion for example through the use of rigid racking which puts them at risk of being unable to adapt to changing business requirements.
- Flexibility is key to remaining competitive in today's fast-paced marketplace, warehouse operations that make plans for future growth can stay one step ahead of their competition.
Insufficient Focus on Workplace Well-being & Safety
Substandard workstation design and insufficient safety measures, such as emergency exits and warning signs, increase the risk of accidents, injuries, and reduced productivity.
Lack of Technology Adoption and Automation
- Failure to adopt the latest technology tools offered through automation hinders efficiency and productivity.
- Making use of data analytics & insights assists with optimised warehouse operations and efficiency
Important Things to consider:
- Identify the warehouse's main function, product categories, and material handling requirements.
- Evaluate the warehouse's existing layout, operations & workflows, pinpointing areas for improvement, inefficiencies, and bottlenecks.
- Make use of flexible storage and shelving, maximising vertical space, streamline aisles, and make things easily accessible.
- Designate specific areas for picking and packing to streamline order fulfilment and cut down on travel times.
- To maximise production and efficiency, use automation and/or technology, such as conveyor systems and warehouse management software.
- Make sure solutions are flexible and adjustable.
Recommended Best Practice for Implementation
- Involve stakeholders in the design process.
- Implement the new layout in phases.
- Provide comprehensive training and support.
- Continuously monitor and adjust the layout as and when needed.
Brief Bio: Rina Redelinghuys, Customer Services Executive, Cquential, part of the Argility Technology Group.
Rina Redelinghuys is a highly experienced, results-oriented project and customer service executive. Her range of expertise includes supply chain management – demand forecasting, inventory optimisation, and supply chain network design – logistics, data analytics, business analysis, ITIL, project management and procurement. Her long number of years in the warehouse industry has led to a deep understanding of warehouse operations, inventory, and storage optimisation, as well as all elements of transportation management.
Rina is highly skilled in data analysis with regards to logistics and the identification of trends leading to optimisation of operations. Her decade at Cquential has led to the development of a profound understanding of technology in the sector, including back-end competence in setting up ERP software systems and more. In her current role she is responsible for projects and services, customer relationship building, business development, product roadmaps, and operations.
