filter-solution-warehousing Articles

New e-book helps you discover and build the optimal warehouse to meet your unique business needs

When it comes to creating your perfect warehouse strategy, there are a wide range of challenges to consider. From demand variability and shipping windows to managing costs and meeting customer expectations to simply figuring out the best way to organize your inventory, many elements must be factored in for not only what you’ll need today, but also what you’ll require tomorrow.

Penske has put together a guide to help users think about and plan for the optimal warehouse to meet their distinctive business needs. We examine all facets of the warehousing process, including:

  • Warehousing options
  • Whether to lease, buy or build
  • Site considerations
  • Making the most of your warehouse space
  • Inventory management best practices
  • Warehouse management technologies
  • Smart warehouse technologies
  • Labor management

As a renowned leader in the warehouse and supply chain industry, Penske works with businesses all over the world to make the most of their square footage and minimize the risks that can hinder warehouse operations. Our strategic warehouse designs influence efficiency in all your processes, from inventory control to production tactics and labor management.

With warehouse design playing such a critical role in an efficient supply chain, you’ll enjoy this in-depth guide that helps direct you through important factors to consider when planning your warehouse operations.

Maximizing space within a warehouse and positioning items to improve efficiency can add up to significant financial and time savings. The layout and design of a warehouse and a distribution network should be an ongoing process. Shippers can improve their food warehousing and distribution with these six strategies:

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Cross-docking – unloading product from an inbound truck and loading it directly onto an outbound truck – is a well-established logistics practice that is growing in importance as a way to manage risk in the supply chain.

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The interest among foreign shippers to start selling their products on the European market is high and rapidly increasing. Annual figures from NDL/HIDC, responsible for representing and promoting the Dutch logistics industry, show stable double-digit growth figures for foreign logistics investment projects.

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Improve productivity, quality and safety from the ground up

If you're ready to give your employees the reins – and rewards – for establishing efficiencies in your warehouse, it may be time to look into labor management software. Choosing the right labor management program is important, yet even more important is making the program successful for your business.

To learn more, read our white paper, "Turn Your Warehouse on Its Head." You'll discover how effective implementation of labor management software may help you to improve warehouse productivity, enhance quality and ensure a safe environment.

Among the topics covered:

  • Seven key benefits of labor management software. Learn how the right system can help you better balance workload, track productivity, reward associates and provide appropriate coaching and feedback.
  • Getting your employees to own the process. Doing so creates empowered associates who hold each other accountable for safety and productivity.
  • Effective leadership training solutions that help local supervisors and managers to become trusted mentors.
  • The four phases of implementation that will ensure your labor management software delivers the results you need.
  • Six steps to assessing your warehouse efficiency, including assessing your yard, inbound and outbound processes, along with task management, inventory management and warehouse labor.

E-commerce is more prevalent today than ever. Whether it’s a popular piece of clothing or the newest gadget, online shoppers want their purchases to arrive at their doorsteps sooner and quicker. And the same can be said about their groceries.

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Food and beverage products in the fresh channel must be delivered on time and intact, which means retailers must work with reliable, proven supply chain and cold storage partners. To ensure success, retailers should look for these five key traits in their cold storage provider.

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Many organizations scramble to purchase costly warehouse management systems (WMS) in the hopes of solving all their warehouse challenges, only to be disappointed when the system fails to meet their expectations.

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The world of the food warehouse is exploding with new technological advancements to ensure product safety and reliability, while reducing spoilage and improving accuracy.

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Free white paper explores how technology maximizes operations, ensures compliance

Ensuring the safe and reliable storage and transportation of fresh foods has never been more important than now, especially with the ongoing implementation of the Food Safety Modernization Act (FSMA). The food warehouse plays a crucial role in keeping fresh foods fresh. To be safe and compliant, warehouses must have a logical design and layout, maintain the proper temperature zones for specific products, and utilize the right software for optimal efficiency.

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Download our free white paper to learn how to lower costs and provide better service

Rising operational costs, economic pressures and the growth of e-commerce are among the market forces that can drive up logistics costs in manufacturing. Companies must respond by finding ways to reduce and control the cost of logistics operations.

There are many ways to achieve these goals, including incentivizing trucking companies to carry a manufacturer’s freight and reconfiguring freight networks to run more efficiently. These strategies can also yield long-term benefits.

Manufacturers that systematically pursue cost-cutting strategies will become more adept at analyzing their logistics expenditures and improve their ability to translate best practices into lower costs and higher service levels. Download and read the report today.

In the global manufacturing industry, inconsistencies related to seasonal volumes are common. Volumes can fluctuate based on the weather or the time of year. If not managed properly, that inconsistency can result in waste and clutter, which increases costs.

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Understanding exactly what is inside of the warehouse and where it is located can help manufacturers speed fulfillment, cut costs and improve customer service.

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Receiving shipments on time isn't enough these days. Instead, automotive manufacturers' shipments must also arrive in the order they are needed. To do so, a manufacturers' just-in-sequence supply chain must be optimized.

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Efficient warehouse design is the foundation of an efficient supply chain, one that can service your customers in a timely fashion. When warehouse design doesn't evolve with regular or unexpected changes in operations, products or personnel, it can leave your whole supply chain languishing.

Penske Logistics designs streamlined warehouse layouts that are built for the most efficient access to goods and overall execution of labor within your warehouse. Team up with us to implement a data-driven warehouse design strategy that will maximize your performance inside and set you up for success outside your distribution centers.

Technology-Driven Modeling

Every warehouse has its idiosyncrasies. We work with businesses all over the world to make the most of their square footage, and minimize the risks that can hinder warehouse operations.

You have to know what you're working with and what you're working toward to design and implement the perfect warehouse layout. Some of the research we perform to influence good warehouse design is related to:

  • Facility location and size analysis
  • Capacity analysis
  • Equipment analysis
  • Cross-dock layout and scheduling
  • Facility simulation modeling
  • Process flow analysis
  • Labor and material-handling equipment utilization
  • Operational engineering and process development

Backed by data, you can design a warehouse to address all of these variables affecting operations. You'll find that strategic warehouse designs influence efficiency in all your processes, from inventory control to production tactics and labor management.

Making the Most of Your Space, Every Day

Penske's warehouse designs help make the most of the space you already have. Our experts keep up with your business to create designs that ensure efficient material handling and economical storage, while protecting the safety of people and product. Moreover, the designs we implement ensure facilities can be modified to accommodate changing needs without major expense or disruption. Keep Penske Logistics in your back pocket—we're working for your continuous improvement.

7 Common Questions About Warehouse Design

What is warehouse design?

Efficient warehouse design is the foundation of an efficient supply chain, one that can service your customers in a timely fashion. It is the physical layout and placement of products for the most efficient movement of goods.

Why is warehouse design important?

The right warehouse layout should help to improve the flow of production and distribution and make the most of your budget. A well-designed warehouse layout also enables better administration of the workforce, procedures, and inventory.

What are the various factors to be considered in warehouse design?

When designing a warehouse, there are many things to consider. Some of the most impactful factors include:

  • The goods and products the facility is designed to hold
  • The physical characteristics of the building
  • The required equipment that is necessary to operate the warehouse
  • The circulation of goods throughout the facility

What are the different types of warehouse design?

There are three main types of warehouse design: U-shaped, I-shaped and L-shaped.

The most typical layout is a U-shaped warehouse product flow. Due to the proximity of the shipping and receiving ports in this arrangement, resources at the dock, including workers and material handling equipment, can be pooled. Additionally, this arrangement reduces product handling and provides great cross-docking capability.

The I-shaped warehouse takes advantage of the two ends of the warehouse layout and uses them as the loading and unloading areas. The longer center section of the I is used as the picking, packing, and receiving areas as well as general storage areas providing ample space for the warehouse.

The U-shaped warehouse keeps everything apart and streamlines inventory flow. The U-shape also aids in preventing bottlenecks by having incoming and leaving shipments on parallel sides. Workers can move goods between shipping and receiving quickly because they are located on the same side of the building.

What is product flow in a warehouse?

Product flow is the movement of goods throughout the warehouse designed to get the products from supplier to consumer. Products are often classified using the ABC analysis.

A movers typically represent products that have the most turnover and as result, they are of strategic importance. A goods are typically placed in the lower areas of a warehouse, with direct and easy access for the operators, and close to the shipping docks.

B movers are often these goods which are replenished more slowly, and their value and importance are less than those of A products.

B SKUs carry importance because they could make the move to A-turnover products or, conversely, become C goods. B products are located in intermediate-height areas. They can’t be accessed as directly as A products, but they are also not inaccessible either.

Products that are identified as C movers are typically the most least requested products by customers. Since these items are not in high demand, they are touched very infrequently and therefore occupy the highest locations and the distances furthest away from the dock.

Which warehouse design is the most commonly used for product flow?

For product flow, the most typical layout is a U-shaped warehouse. Due to the proximity of the shipping and receiving docks, dock resources including manpower and material handling equipment can be used jointly in this layout.

What are the objectives of warehouse design?

Effective warehouse design improves operational effectiveness, cuts costs, and raises customer satisfaction. Utilizing resources wisely while satisfying customer expectations is the primary objective of successful warehouse design.

Things have a way of getting out of hand as you experience growth and face changes in your supply chain or your customer base. Suddenly you have an over-sized, over-extended network that meets your customers’ needs, but isn’t cost efficient. We can help you identify the right number of distribution locations, in the right places.

We’re committed to solving one of your company’s most widespread challenges. It’s our business to redesign logistics networks for maximum speed and flexibility. To ensure every link in your supply chain is strong, our experts assess:

  • Site selection
  • Mode selection
  • Routing
  • Inventory and transport costs

Global Reach, Local Know-How

Our distribution and network design expertise spans multiple continents. With a complete understanding of your specific distribution needs and operational conditions, we’ll be your road map to future success.

We set up your network for speed and efficiency by selecting and analyzing locations for your facilities and integrating them into your supply chain. Our goal is to help you anticipate how the local realities affect operations and address them proactively throughout your network, whether it’s nationwide, regional, or local.

The Connecting Link in Your Delivery Chain

To streamline delivery and improve costs, our experts:

  • Establish the optimal facility assignments within your network
  • Determine the ideal number, placement and size of facilities
  • Coordinate shipping and delivery across all business units
  • Provide actionable transportation mode analysis
  • Offer counsel on continuous realignment
  • Analyze the impact of network changes in sourcing, etc.

6 Common Questions About Network Design

What is network design? 

The planning and design of manufacturing, warehousing or distribution facilities, as well as transportation routes, with an emphasis on speed, efficiency, and cost, is referred to as network design. Sometimes it's necessary to revise network architecture to account for changes in the consumer base, the supply chain, or business methods that are more sustainable. For instance, a company may decide to create a more efficient distribution network in order to decrease waste, save money, and lower its carbon impact.

What are the five elements of network design? 

The five elements of network design are as follows:

  • Storage, warehousing and materials handling
  • Packaging
  • Inventory
  • Transport
  • Information and Control

Why is logistics network design important?

Network design is a key component of any supply chain. The main goals of any supply chain design are to reduce costs associated with transportation, working capital, and inventory. Additionally, a stable network design improves visibility, identifies chances for cost savings and minimizes risk.

How does network design impact the supply chain?

The structure of the supply chain and the limits they impose on how the other supply chain drivers may be employed to either reduce supply chain cost or boost responsiveness poses a substantial influence on supply chain performance.

What are the three levels of supply chain network design? 

The three levels of supply chain network design are the strategic level, tactical level and operational level.

The Strategic level involves the creation of long-term plans outlining the organization's overarching objectives and goals falls within this level of supply chain management. It requires determining and evaluating the firm's strengths and limitations, choosing strategically where to concentrate resources, and developing a vision for the future. Such level of planning focuses on long-term choices and takes the larger picture into account.

Tactical planning entails creating detailed strategies to accomplish goals within the parameters of the strategic plan. These plans could include identifying priorities, creating goals, and developing plans to reach those goals. Planning for particular goals and objectives is the emphasis of tactical planning.

The Operational level is defined by putting the tactical strategies into effect to accomplish them. This often involves working with several business divisions to coordinate systems and processes that assist in execution and making sure that all stakeholders are always updated on the status. Operational planning focuses on daily duties and specifies how these tasks should be completed to meet the goals of the business.

What are the objectives of network design in supply chain? 

The goal of supply chain network design is to strike a balance between service levels and expenses associated with manufacturing and purchasing, inventory carrying, facilities, transportation, and other costs.