Rising customer expectations, demands for shorter delivery times and an ever-increasing product range are changing the requirements for warehouse locations. At the same time, the range of available technologies is growing – from shuttle systems and autonomous vehicles to automated order-picking solutions. This makes warehouse layout and space planning a strategic task. Companies must make more comprehensive decisions about which systems are compatible, how material flows can be organised efficiently, and how existing space can be utilised optimally.
Analysis of the initial situation – From processes to a functioning warehouse concept
Before discussing systems, technologies or layouts, success is determined by something entirely different: understanding the reality within one’s own warehouse. This is precisely where things often become critical. For what looks like clear master data on paper frequently turns out, in practice, to be incomplete, contradictory or simply unusable. The result: planning is based on assumptions rather than facts. Yet analysis is not a formality, but one of the most important levers. Every intralogistics planning exercise begins with the core processes: goods receipt, storage, order picking, packaging, sorting and goods-out. Crucially, the initial focus is not on space or layouts, but on understanding the workflows. Following the principle of ‘from high-level to detailed planning’, processes are structured and linked together. This results in an initial rough material flow, which forms the basis for all further decisions. If you do not truly understand your product structure, order patterns or growth drivers, you cannot develop a system that works in the long term. The real challenge, therefore, lies not only in the choice of technology, but in taking an honest look at one’s own processes. Only in the next step is a rough layout developed from this. The details follow later: suitable warehouse technology, optimal use of space and efficient design of individual process areas. One thing always remains crucial: only when data is cleaned up, interrelationships understood and developments realistically assessed does a robust foundation for further planning emerge.
Development of Layout Variants
Understanding the processes leads to the next step: translating them into a suitable warehouse layout. In practice, there is rarely a ‘perfect’ first draft. Requirements change, data is refined, and new constraints – particularly in brownfield environments – emerge. Furthermore, space is often limited, expensive or subject to structural constraints. At the same time, demands on throughput, flexibility and automation are inclining. The crucial question is therefore not “Which system is the best?”, but “Which system really suits my space, my processes and my intended growth path?”
The dimensioning of the warehouse space forms the basis of system and warehouse planning, as it significantly determines the structural framework conditions. This is initially a rough first approach, in which storage systems can be divided into three basic categories in terms of space utilisation:
Square spaces – are more suitable for automated bulk storage.
Rectangular, elongated spaces – are better suited to longitudinal storage.
Irregular spaces in terms of length and width – must be examined individually and in detail.
This classification already provides an initial rough assessment of whether an automated small-parts warehouse could be used in the preliminary planning. It is important not to overlook the influence of the available building space: block storage systems, for example, only allow for a system height of six to twelve metres. Modern automated shuttle warehouses or warehouses with storage and retrieval machines, on the other hand, often utilise building heights of 20 to 30 metres in practice. This can be a key selection criterion, particularly where space is limited or land costs are high. For square areas, row storage systems may also be an option if the height can be utilised to achieve the necessary storage spaces – always in compliance with the relevant fire safety regulations.
The pre-zone: the link between the warehouse and processes
For the layout to work, the pre-zone plays a central role; it connects the warehouse and processes and is often underestimated in the planning stage. Yet it has a major influence on space requirements and performance. It declines depending on the system: whilst compact storage solutions require less space, traditional systems need additional areas for conveyor technology and material flow. This requirement grows rapidly, particularly with high throughput rates. Careful planning of the pre-zone is therefore crucial. An analysis reveals how much space is actually required and enables targeted optimisations, for example through intelligent conveyor technology or multi-storey solutions. This results in a system that not only functions but also makes efficient use of the available space.
Workplaces – Sequencing and Ergonomics
Another crucial component of the layout is the workplaces. As a general rule: manual workplaces must be designed to be ergonomic and safe – this increases space requirements but ensures stable and low-error processes. Automated workplaces are more compact, but are clearly defined by technical and safety requirements. Correct sequencing at the workplace plays a particularly important role in goods-to-person systems:
The challenge lies in finding the right balance. This is precisely where we can help: we design workplaces so that ergonomics, performance and space efficiency work together optimally – tailored to your processes and growth targets.
Increasing complexity in planning
It becomes clear, at the very latest when designing workplaces, just how many influencing factors come together in the planning process. The spatial relationships described above alone often lead to discussions and adjustment cycles during the planning process. Added to this are requirements from standards regarding safety specifications and accessibility – and their impact on functional areas (see VDI 3644). These aspects often conflict with cost considerations, and this alone gives rise to new requirements for the system’s variant development.
From the details to the big picture: What makes for successful layout planning
Rising customer expectations, shorter delivery times and expanding product ranges were the starting point for every consideration. This is precisely what leads to the key insight: An efficient warehouse layout is not created by selecting individual technologies, but through the interplay of processes, space and the system. Selecting the right warehouse system is always just one component of the overall concept. What is crucial is that the system as a whole meets customer requirements for material and information flow whilst being designed to be cost-optimised. The foundation for this remains a reliable database, the preparation of which continues to pose a central challenge. Planning always involves developing variants and an iterative approach, from rough planning right down to the details. Modern digital tools can provide valuable support for this process, but they do not replace the tried-and-tested methodological steps.
An efficient warehouse layout is created step by step – from the analysis of processes through the development of the layout to the concrete design of the individual areas.