Your warehouse staff probably walk several kilometres every shift.
They’re bending, reaching, lifting, and moving between zones that aren’t quite logically organised. By the end of the day, they’re tired, and that tiredness slows everything down.
Brilliant warehouse design is about whether your facility helps or hinders the people working in it.
Layout Efficiency
First off, position fast-moving items close to packing and dispatch. Slower-moving stock is de-prioritised and may be assigned to locations further away. Follow the humble 80:20 rule: if your top 20% of products account for 80% of picks, position those items within metres of the packing stations.
It’s also a good idea to group related products together. If customers typically order certain items together, store them in the same zone so picking doesn’t require touring multiple areas. Design clear pathways that don’t create bottlenecks when multiple staff need access simultaneously.
Ergonomics That Prevent Fatigue
Poor ergonomics tires staff, slowing productivity throughout the day. A quality warehouse fit-out considers how people work. Key factors:
- Frequently accessed items at waist height reducing bending and reaching
- Heavier items between knee and shoulder height preventing back strain
- Packing stations at comfortable working heights with adequate space
- Proper lighting throughout reducing eye strain and mistakes
Reserve higher shelves for slower-moving inventory, accessible only with proper equipment. Don’t force repeated bending, stretching, or awkward lifting because racking design ignores workflow.
Using Height To Expand Space and Operations
Most warehouses have several metres of unused height above their racking. A warehouse mezzanine floor uses the wasted height by creating an additional level above your existing operations, effectively doubling your storage capacity without expanding the building or moving to larger premises.
The steel platform sits above with access via stairs or goods lifts, so the ground floor keeps operating normally whilst you’ve gained a whole new storage level above.
Many businesses find the installation pays for itself within months just from the extra capacity, as you can store more stock without the disruption and expense of relocating.
Creating Outstanding Warehouse Spaces
What’s causing problems in your warehouse right now? Is the layout creating bottlenecks? Are staff struggling with awkward access to popular items? Does the space just not work how your operation has evolved?
At Spaceway, we’ve been solving these challenges for over 50 years. We start by understanding what’s not working and why, then design solutions that fit your actual operation rather than forcing you into generic warehouse layouts.
Whether it’s mezzanines for capacity, better racking for efficiency, or a complete warehouse fit-out that transforms how you operate, we work with you to create warehouses that improve productivity.
Get in touch to discuss what’s not working in your warehouse.