Design of a warehouse: from the feasibility study to hand-over

Designing a warehouse is a complex process that requires meticulous planning and strategic decision-making. From the initial feasibility study to the final hand-over, each phase plays a crucial role in ensuring the facility meets operational needs, maximizes efficiency, and adheres to budget constraints. This article explores the key steps involved in warehouse design, including site selection, layout planning, material handling considerations, and technological integration. Whether you are developing a new facility or optimizing an existing one, understanding these stages can help you create a warehouse that supports seamless logistics and future growth.

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Organisation of distribution network

• Master plan and factory layout
• Warehouse logistics
  • Design of internal material handling systems
  • Design and re-organisation of traditional and highly automated warehouses
  • Dynamic simulation of handling systems
  • Continuous improvement actions (e.g., times and methods)
• Outsourcing of transportation and warehouses
• Forecast of demand and stock management
• Lean production
• Training in supply chain

Audit

We identify the strengths and weaknesses of the actual warehouse and define possible interventions highlighting the expected benefits, the prerequisites for their implementation, any risks, time and resources required.

Feasibility study

It defines the strategic, technological and organizational options, to eliminate the weaknesses and to achieve levels of excellence, with regard to efficiency, accuracy and service. It identifies alternative solutions, which are analyzed and presented defining the valences in terms of obtainable results, budget and ROI, operating costs, operational flexibility, implementation time.

Detail Project

It is the analytical design phase of all components of the Warehouse, to issue drawings and technical and functional specifications necessary for the launch of tenders.

Management of the realization

In support to the Customer, we offer technical assistance to the management of contracts, we verify technical content and project schedule issues. Logistics project management is carried out, the on site supervision of the building yard, staff training and assistance in testing, start-up and commissioning.

Periodic monitoring of the efficiency

After the start-up of the warehouse, the results actually achieved are monitored to identify the reasons for the deviations from the goals that were set. The scope is to establish new goals, by removing the problems with the logic of "continuous improvement".

Scope of work

Project team

Collection and data analysis

Stock analysis

Comp.	Descrizione	N° Codici	%	Progr	N° Medio Pallet in Giac.	%	Progr	Pallet x Cod

Current Situation

Stock – Projection design point

Materials flows analysis

Materials flows analysis

Development of alternative solutions

Each alternative solution must be characterized in terms of:

• Master Plan of the site
• Warehouse layout: design of logistic equipment (storage and material handling means) according to project requirements
• Operative criteria: put-away rules, warehouse storage mapping, picking processes (per single order, batch order picking, sorting, etc.), handling processes
• Commitment of the staff (and relevant running costs)
• Other running costs (maintenance, consumption materials, insurance, consumptions, etc.)
• Investment costs and computation of return
• Project time schedule / planning of implementation stages

Development of alternative solutions

Development of alternative solutions

Estimate of investment

Comparison of alternative solutions

Project schedule – GANTT

The objectives

Detailed project

• Detailed analysis of functional, technical, management, and system aspects developed in the feasibility study
• In-depth examination of project data, where necessary
• Definition of the final layout and drafting of drawings (plans, views, sections, details)
• Integration of the logistics project with building and plant aspects (sprinkler system, heating/cooling system, lighting, compressed air, etc.)
• Process definition and drafting of operational procedures
• Creation of a detailed Gantt chart

Operational procedures

Construction drawings

DYNAMIC SIMULATION

• Collection and design of the conceptual model
• Development of the model using AutoMod
• Execution of simulation experiments
• Analysis and validation of results
• Identification of potential improvements at the plant level and operational strategy optimization

3D animation

PURCHASE PROCESS

Definition of the Vendor List and selection of purchase methods

• Issuance of tender documents, including:
  • General tender specifications (aligned with supplier practices)
  • Technical specifications, covering:
    • Handling and storage systems (stacker cranes, LGVs, conveyors, etc.)
    • Racks (self-supporting, traditional PP, shelving systems, etc.)
    • Forklift trucks
    • Other equipment (palletizers, taping machines, end-of-line packaging, truck loading/unloading points, etc.)
  • User requirements, including:
    • Operational management software
    • RF terminals, voice systems, etc.
• Bid collection and analysis, including:
  • Critical review of supplier bids and drawings
  • Clarification and standardization of proposals
  • Technical and economic specifications
• Support in negotiations
• Technical verification of contracts

Sample of Technical specifications

Hw and Sw Structure

BUILDING PROJECT/ASSISTANCE TO REALIZATION

BUILDING PROJECT AND ASSISTANCE TO REALIZATION

Among the main activities, we can mention:

• Critical examination of building drawings and review of supplier documents related to automation
• Collaboration in updating the project Gantt chart, drafted and managed by the Customer
• Assistance in the execution of the Factory Acceptance Test (FAT), including review and approval of supplier documentation by the Customer
• Execution of periodic field audits and assistance in compiling certificates demonstrating the completeness of supply and construction completion
• Monitoring supplier activities and supervision during the commissioning phase
• Review of documents and assistance in the execution of the Site Acceptance Test (SAT)
• Compilation of the hand-over document, in collaboration with suppliers, with joint approval by the Customer
• Collection and transmission of as-built documentation from suppliers to the Customer