Amphora makes it possible to design warehouse layouts using a structured system in Excel. This functionality allows the definition of Shelf Cells and Walk Cells, ensuring that all storage units are accessible and organised efficiently. The aim is to optimise picking routes, streamline order picking and improve movement in the warehouse with an accessible and efficient structure.
What are layouts?
A layout is a document divided into cells showing the layout of the warehouse. There are two main types of cells: Shelf (shelving) and Walk (walkable spaces).
Even so, this information is not enough to be able to report on how the space is distributed. It remains to be defined from which part of the shelf the product can be accessed to picketed.
Description: Shelf cells (S)
The 4 shelves are accessible because they are connected with a walkable part. But from which part of the shelf is it accessed?
- Accessible from the left (SL, shelf left).
- Accessible from the left (SL, shelf left).
- SL and SR can be connected, something common in any warehouse to make the most of space by putting two racks together.
- A shelf can also be accessed from the left and right (SLR, shelf left right) to allow picking from two parallel aisles.
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If the shelves are placed horizontally, the same logic can be applied with SU (shelf up), SD (shelf down) and SUD (shelf up down).
IMPORTANT!
It is mandatory to assign the accessibility type to all cells. If this is not the case, the layout is incorrect.
WARNING! THIS IS INCORRECT:
Here are two examples of how NOT to organise the warehouse layout. In this way the shelves are NOT accessible.
In the image on the left, the pickers would not be able to access the product because, according to the signs, the exits of the racks (SL and SR) go towards the middle.
The same is true of the image on the right.
Description: Walk cells (W)
The 'W' indicates that a space is walkable, you can walk through It is very important to bear in mind that:
- You must mark with a 'W' all the cells that can be walked through.
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The entire warehouse must be connected with 'W'.
- All shelves (S) must be accessible, i.e. they must touch at least one 'W' on the side.
IMPORTANT!
When designing the warehouse layout it is important to represent reality as much as possible. That is, if one aisle is wider than another, it should be marked with more 'W'.
WARNING! THIS IS INCORRECT:
In this picture the layout is NOT correct because all the shelf blocks are not connected. There is a blank space in the middle.
Remember that the ENTIRE warehouse must be connected.
Are there types of 'W'?
Yes, they exist, but it is optional. They are only used on very specific occasions and in strictly necessary cases, e.g. in warehouses that are normally very busy. The different types are the same as in the case of Shelf cells (S):
- W: you can walk in all directions.
- WL: You can only walk to the left.
- WR: you can only walk to the right.
- WLR: you can only walk left or right.
- WU: You can only walk upwards.
- WD: you can only walk down.
- WUD: you can only walk up or down.
How do I make the layout of the warehouse?
The layout is done by means of three Excel documents (plus an optional one in the case of large warehouses). Each shows similar and related information. When designing the layout, we recommend creating the first sheet and then duplicating it and modifying the information it contains. A sheet represents a layer where each cell is a square that has the same size (one unit of distance per cell). The cells must be square.
IMPORTANT!
The cells must be square and the blocks must be the same in all three documents.
Here you can download the example Excel document to create your warehouse layout. A Google Sheets file will open in Google Drive and from there you can download it [File - Download - Microsoft Excel (.xlsx)] for editing.
What steps should I follow to create the warehouse layout?
STEP 1: LAYOUT
The first document to create is the one explained in detail above.
STEP 2: BLOCKS
In the second document, you must define the numbers for each block. Make a copy of the first sheet to keep the same block structure and apply the relevant changes by following these steps.
This is an example of how to do it correctly:
Some correct and incorrect examples are shown below to facilitate the understanding of what the information in the document should look like.
A block is a single shelf, therefore it cannot be divided.
This is incorrect because block 11 and 12 are divided:
This is correct. Each block is a unit:
A block must be linear
This is incorrect as block 10 is not linear:
This is correct since, in order to realise the 'L' shape, different numbers are assigned to each block to respect the linear shape :
A block cannot be diagonally aligned
This is incorrect:
All blocks must be accessible
This is incorrect because block 11 is not accessible and even parts of block 14 are not accessible.
This is correct because blocks 11 and 14 are now accessible:
STEP 3: BLOCK_DIRECTIONS
For the third document you also have to make a copy of the first sheet to keep the structure of the blocks. Here, you will have to report the address of the locations within the blocks. Below, you can see examples for all directions.
These locations go to the right (R):
These locations go to the left (L):
These locations go downwards (D):
These locations go upwards (U):
STEP 4: ESTABLISH ZONES
This is an extra step that can be applied in large warehouses with the aim of dividing the picking space into different zones to increase the efficiency of the pickers.
As shown in the example, this warehouse is divided into zones. In this case, each zone represents a different aisle but can be organised in the most optimal way to improve the performance of the pickers. Similarly, any number can be assigned to the zones. For example, a number could be assigned according to locations (aisle 3 and 4, zone 3-4; aisle 5 and 6, zone 5-6; and so on).
In short, the goal is always the same: to make it easier for pickers and thus improve warehouse efficiency.