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A well-designed warehouse is the backbone of an efficient, profitable operation. Get it right, and youâll benefit from faster order fulfillment, reduced errors, and a safer working environment. Get it wrong â and you could be dealing with constant bottlenecks, frustrated staff, and rising operational costs.
Whether youâre fitting out a brand-new facility or reevaluating your existing layout, here are some of the most common warehouse design mistakes that quietly kill productivity â and how to avoid them.
đ 1. Poor Space Utilisation
The Mistake:
Leaving valuable vertical or horizontal space underused, or cramming too much into too little, creates inefficiencies and safety issues.
The Fix:
Maximise your available footprint by installing high-density storage like pallet racking or mezzanine floors, and plan for clear, designated work and staging areas. Use vertical space effectively and leave appropriate aisle widths for equipment and pedestrian access.
đ 2. Inefficient Workflow Layout
The Mistake:
Random or poorly planned layouts force staff to zigzag across the warehouse to pick, pack, or dispatch orders, increasing travel time and fatigue.
The Fix:
Map out your material flow â from goods-in to storage to dispatch â and design your layout to support it. High-turnover items should be stored closest to packing and shipping areas, while slower-moving stock can be further back or higher up. Aim for smooth, continuous movement with minimal backtracking
đŚ 3. One-Size-Fits-All Storage Solutions
The Mistake:
Using the same type of racking, shelving, or storage method for every product, regardless of size, weight, or turnover frequency.
The Fix:
Segment your storage strategy. Use pallet racking for bulk items, shelving for small parts, cantilever racks for long goods, and secure cages for high-value stock. Match storage types to your inventory profile to optimise space and retrieval times.
â ď¸ 4. Ignoring Safety in the Design Phase
The Mistake:
Treating safety measures as an afterthought leads to hazards, increased downtime, and compliance issues.
The Fix:
Incorporate safety features from day one:
A safe warehouse is not just a legal requirement â itâs a productive one.
đď¸ 5. Overlooking Future Growth
The Mistake:
Designing a warehouse layout that only fits your current stock levels and workflows, leaving no room for expansion or changes in product range.
The Fix:
Future-proof your warehouse by choosing scalable storage systems and leaving flexibility in your layout for additional racking, new technology, or changes in order profiles. Consider modular racking or mobile shelving solutions that can be easily reconfigured.
đ 6. Underestimating Picking & Packing Efficiency
The Mistake:
Clumping packing stations too far from picking areas, or not providing enough stations during busy periods, slows down fulfillment.
The Fix:
Position packing areas strategically close to high-volume pick zones. Equip them with all necessary supplies (labels, boxes, scanners) to minimise staff movement. Evaluate the feasibility of dedicated fast-pick zones for top-selling items.
â In Summary
Warehouse productivity isnât just about working harder â itâs about working smarter. By avoiding these common design mistakes, youâll create an environment that supports fast, efficient, and safe operations while remaining flexible for future growth.
Key takeaways:
âď¸ Plan space and workflow layouts carefully
âď¸ Match storage solutions to stock profiles
âď¸ Prioritise safety and future scalability
âď¸ Position packing areas and high-turnover stock strategically
Thinking of upgrading or redesigning your warehouse? Contact Usâ we can help assess your space, avoid these pitfalls, and design a warehouse setup that boosts productivity from day one.
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