Top Factors For Warehouse Zoning

The notion of zoning a warehouse involves segmenting the available space into distinct areas or zones to maximize optimization concerning space utilization, cost efficiency, and other relevant factors.

Key considerations for effective warehouse zoning include:

  • Optimal utilization of the available space.
  • Swift and convenient access to stored items.
  • Enhanced visibility and strategic placement of goods.
  • Minimization of storage-related expenses.
  • Decrease in the distances traversed by handling equipment.
  • Ensuring safety within the warehouse environment.
  • Clear identification and marking of each designated area within the warehouse.

Characteristics of the good to be considered

Product characteristics play a crucial role in the zoning and storage process within a warehouse. Important attributes to consider include:

  • Size of the goods: Organizing products by size can lead to reduced handling costs, such as placing larger items in areas that facilitate easy loading and unloading.
  • Inventory turnover: A critical aspect of zoning is that items with high turnover rates should be positioned near shipping areas to minimize travel distances, while low turnover items may be allocated to more distant, less accessible locations.
  • Order preparation: For products requiring assembly or preparation, zoning them in a designated order preparation area can enhance efficiency.
  • Complementary products: Storing items that are frequently ordered together in close proximity can streamline warehouse operations.
  • Incompatibility: Certain products, due to their size, weight, volume, composition, or environmental requirements, cannot be stored together. For instance, chemicals and perishable items must be kept separate. 

The ABC Inventory Zoning Method

A widely utilized zoning technique is the ABC classification method, which is grounded in the 80/20 principle. This method organizes warehouse zones according to specific criteria, such as product turnover rates.

Products that exhibit the highest turnover are allocated to zone A, representing approximately 20% of the total inventory. Following this, products with moderate turnover are designated to zone B, accounting for about 30% of the overall stock. Lastly, products with the lowest turnover are assigned to zone C, which encompasses the remaining 50% of the total inventory..