The consequences of poor planning and design are often costly. Even small oversights, such as inadequately sized dock doors or improperly positioned rack beams, can snowball into large, head-pounding problems. The only way to avoid or counteract this downward spiral is by getting back to the basics: Reassess the current operation, then properly plan and design – or redesign – the facility to create a world class warehouse.

• It must offer consistent high quality service in a facility that is economical to build, efficient to operate, and flexible enough to adapt to changing business conditions.

• Consider cross docking. Move full pallets from receiving, directly to shipping. This will reduce storage space as inventory is eliminated.
  
  
• Consider a detailed slotting of products into the pick modules with ergonomic principals in mind.
  
  
• Use advanced technology such as pick to light, voice systems and radio frequency device.
  
  
• Use mezzanine to improve cubic utilization and reduce space requirements.
  
  
• Put shelving over conveyors.
  
  
• Put pallets racks behind cash flow racks for quick replenishment of popular items.
  
  
• Use the floor location of the reserved storage area as pick locations when a forward picking area is not possible.
  
  
• Perhaps the most important design tip is to allow for the expansion in the design. Dynamic business conditions and changing customer requirements make designing for flexibility a necessity.

• Goods must be classified according to their potential danger during the time of storage in the warehouses.
  
  
• Storage in front of the warehouse exits is strictly prohibited.