How do I redesign a warehouse layout to reduce picker travel time?
Quick Answer
Begin with a data-driven slotting analysis, group high-velocity SKUs near packing, shorten aisles, and add pick-to-light conveyors or AS/RS. Warehouse Cubed uses CAD layout design to reposition racks, create clear one-way pick paths, and integrate automation so your pickers walk less and ship orders faster.
Detailed Answer
Reducing picker travel time starts with facts, not guesses. Warehouse Cubed’s warehouse consulting services begin by downloading twelve months of order history into our slotting software. We calculate SKU velocity, cube size, and order affinity to decide which items deserve golden-zone positions closest to your packing stations. Next, our warehouse layout design team builds a 2-D and 3-D CAD model that right-sizes each pick face and lays out one-way traffic aisles to eliminate cross-flow congestion.
High-volume SKUs are positioned at ground level on pallet racking systems; slower movers are pushed upward or into dynamic carton flow, keeping the pick window tight. For long pick walks, we integrate conveyor systems or pick-to-light zones so employees touch product, not miles of concrete. When SKU counts explode, automated storage and retrieval systems (AS/RS) or vertical lift modules can shrink walk time to seconds while increasing storage density.
The redesign also pays attention to safety: wider end-of-aisle turn zones, floor striping, and protective guarding keep people and forklifts separated. Because every facility is unique, we model several what-if scenarios—then our material handling systems integration crew installs the chosen plan over a weekend to avoid downtime. Clients routinely see 30-50 percent faster order fulfillment and labor savings that fund further warehouse automation solutions.