Warehouse Layout Redesign Analysis With Dedicated Storage Method

Abstract

General Background: Warehouse layout is crucial to manufacturing supply chains because unstructured material placement can increase travel and search requirements during storage and retrieval. Specific Background: Materials were placed randomly according to available space, resulting in mixed storage arrangements and longer material movement paths. Knowledge Gap: The existing warehouse system lacked a structured allocation scheme that considered inbound and outbound activity together with travel distance to input and output points. Aims: This study redesigned the warehouse using a quantitative dedicated storage approach based on material flow, space requirements, throughput, and rectilinear travel distance. Results: The proposed layout reduced total travel distance from 3,480 m to 3,174 m, representing a decrease of 306 m or 8.79%. Metal bars were allocated to slots C and F, steel profiles to slots B and E, and metal sheets to slots A and D. Novelty: The study provides a dedicated storage allocation model that integrates throughput per space requirement with proximity to warehouse input and output points for three material groups. Implications: The proposed arrangement provides a structured warehouse layout alternative for reducing material handling distance and simplifying material identification during storage and retrieval operations. Highlights: The proposed layout lowered total travel from 3,480 m to 3,174 m. Metal bars occupy slots C and F; steel profiles occupy B and E. Metal sheets are assigned to slots A and D in the recommended arrangement. Keywords: Dedicated Storage, Manufacturing Industry, Material Handling, Warehouse layout