Warehouse Layout Design
Project
Objective
• Introduce students to the TDL Career
Cluster: Warehouse and Distribution
Center Operations
– Storage and Distribution Manager
• (Content Standard #1)
• Introduce Students to Warehouse
Operations
• (Content Standard #3)
Warehouse Operations
• Warehouse:
– A warehouse is a commercial building
used for storage and distribution of goods.
– Warehouses are used by manufacturers,
importers, exporters, wholesalers,
transport businesses, etc.
Warehouse Layout
• Warehouses must be laid out so they
can function in the most efficient
manner possible
• Different industries have different
warehouse layouts
– EXAMPLE: Food warehouses may have a
freezer section, cooler section, and dry
foods area.
Warehouse Layout
• Racking and isles
always runs toward the
dock doors when in the
same room as the dock
doors.
• Racking must also take
in consideration any Ibeams or other
obstructions.
Warehouse Layout
• Each section of racking
is called a “bay.”
• Each bay usually holds
2 or more pallets.
• Racking is usually 1 to
6 bays high (depending
on how much space is
available in the
warehouse.
• Each bay usually has a
label with a
identification number.
Warehouse Layout
• Each section must
have 3” on each
side (front and back)
free for the pallets
to “hang over” the
racking.
– This is a OSHA
Standard
3 inches for each pallet
Warehouse Layout
•This is an example
of what happens
when the racking
does not have 3” on
each side!
•A standard pallet is
usually 40” wide by
48” deep
•Most pallets cannot
be stacked higher
than 60”
Warehouse Layout
• A functional design must also take into
consideration the isle space (area
between the racks.)
• If the isle does not allow enough space
for the material handling equipment
(fork lifts and pallet jacks) to function
properly, productivity goes down
greatly.
Warehouse Design Project
• For this project, you will use AutoCAD
to layout a floor plan for a food
distribution warehouse.
• You will be responsible for creating a
layout that is effective and efficient.
• You will also be responsible for
submitting a “bid” or price tag for the
racking and fork lifts included in this
solution.
Warehouse Constraints
• The total area of this warehouse is
roughly 194’ x 173’ not including walls
and dock
• Rooms included in the warehouse are:
– 2 Dry Goods Rooms
– 3 Cooler, or Refrigeration Rooms
– 1 Freezer
Racking Constraints
• Racking
measurements are
as follows.
• Each section will be
4 bays high
• Each bay =$1,000.00
($1,000.00 x 4 bays
high = $4,000.00 per
section)
3’ 6”
7’ 11”
7’ 8”
3’
Material Moving Equipment
Constraints:
Chose one of these fork trucks for your warehouse design.
• Yale SS-BE
– Isle width:
114”
– $35,000.00
– 4,000-5,000
lbs
• Yale NS-AF
– Isle width 90”
– $50,000.00
– 4,000-5,000
lbs
• Yale NTA-SA
– Isle width: 66”
– $75,000.00
– 3,000-4,000
lbs
Bid
• Number of bays in your design x
$1,000.00 per bay = total racking cost
• Cost of fork lift you selected to go
along with your design = total material
handling equipment cost
• Total Racking Cost + Total Material
Handling Equipment Cost = Total Bid