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Warehouse Layout Design

The design and layout of your warehouse impacts the speed, cost and quality of service your customers receive. We help our clients to redesign and reconfigure their warehouse to create improvements that reduce warehousing costs and improve customer satisfaction.

About our service

Warehouse layout design

At Hatmill, our warehouse design and layout service is dedicated to transforming your warehouse into an efficient, productive, and cost-effective operation. We assess your current setup and determine what your optimum layout is to reduce cost and improve efficiency.

We use data analytics and ergonomic principles to create optimal layouts, storage solutions, and improve overall operational performance. By partnering with us, you’ll benefit from a tailored approach that addresses your unique needs, driving greater efficiency and supporting your business growth.

Why is a good warehouse design important?

Implementing an effective warehouse design sets the tone for all warehouse activities it undertakes. An optimised layout also reduces travel distances for people, speeds up picking and packing processes, and minimises errors. Ultimately, these factors lead to faster order fulfilment and increased customer satisfaction.

Process & considerations

The Hatmill approach to warehouse design & layout

Our warehouse design and layout approach is focused on producing the most efficient and effective solution for your business needs. Helping optimise space and ensuring a smooth flow of goods through your warehouse, our process is effective and backed by data. Here’s how we do it:

Needs assessment

We’ll begin by conducting a thorough needs assessment to understand the specific requirements of your warehouse operations. This involves analysing current workflows, storage needs, inventory levels, and peak activity periods. Understanding these elements helps in designing a layout that meets your unique operational demands.

Space utilisation analysis

We’ll then perform a detailed analysis of your warehouse space to identify opportunities for better utilisation. This includes evaluating the current layout, measuring available space, and identifying underused areas. The goal is to maximise storage capacity while ensuring efficient movement of goods and personnel.

Layout design

We will then develop a  detailed layout design that incorporates findings from the needs assessment and space utilisation analysis. This step involves creating floor plans that optimise the placement of storage racks, workstations, and equipment.

Technology integration

Often we’ll then suggest using technologies such as Warehouse Management Systems (WMS) and automation solutions into the layout design. These technologies improve inventory accuracy, reduce the reliance on labour, streamline order processing, and enhance real-time tracking of goods.

Implementation planning

We’ll then create a comprehensive implementation plan that outlines the steps for transitioning to the new layout. This will include scheduling the rearrangement of storage areas, installing new equipment, and training staff on updated processes.

Continuous improvement

We will establish a system for continuous monitoring and improvement of the warehouse layout. Continuous improvement ensures that the warehouse layout remains efficient and adaptable to changing business needs.

“We chose Hatmill due to their reputation and proven track record in warehousing design and move management. They always took the time to engage with key stakeholders, understanding the business needs before designing their solutions, their ability to keep the project on track and the team focused enabled us to complete the complex transition from two warehouses to a single new site ahead of schedule.”

– Paul Roughley, Group Operations Director, CMS

Review and recommend

We will review the activities that take place in your current warehouse operations and check them against warehouse layout best practices. We’ll review the impact of the existing layouts on productivity. We will identify opportunities for improvement and then model the outcomes of different options to show the potential increases in efficiency and ROI. We can also help you design and deliver the warehouse improvements and manage the change.

Is warehouse automation the way?

We’ll help you consider whether warehouse automation is a viable solution for your operations. We can compare the potential of automated warehouse solutions against optimising your existing warehouse technology, equipment and infrastructure. We can then manage the implementation of any changes, minimising disruption to ongoing operations.

FAQs

What should you know?

  • Accessing your products is crucial if you want an efficient operation. Different goods require different warehouse layouts and it takes planning to arrive at the perfect design. We’ll help you to develop the right layout for your warehouse depending on your unique needs. 

    Our team will consider factors such as product type, storage requirements, and workflow efficiency. By analysing your inventory, order frequency, and space constraints, we’ll create a tailored layout that maximises space utilisation, enhances productivity, and ensures easy access to your products, ultimately improving overall operational performance.

  • Every warehouse area is important, and they all must work in conjunction with each other.  From goods-in through to despatch, each plays an important role and needs careful consideration when designing the layout for your warehouse.

Case studies

Our work

From initial concept through to end of cutover, Hatmill worked to scope, project manage and deliver Greggs’ new, state-of-the-art £26m Balliol National Distribution Centre.

The facility consolidated Greggs’ legacy network of 4 external storage sites into a single, purpose-built national Distribution Centre and is estimated to save 7% of total mileage a year in transport emissions.

Read More about Greggs Balliol National Distribution Centre

Automation

Greggs Balliol National Distribution Centre

Greggs’ state-of-the-art automated DC – a 32m high, 40,000 sq. ft. hypoxic automated freezer extension – thaws out frozen storage capacity issues.

""Throughout our time working with Hatmill, I have remained impressed with the organisation, focus and tenacity of the team, and they have been instrumental in helping our organisation reach some critical decision points. The team are engaging, personable and a pleasure to work with, and operate seamlessly alongside Greggs colleagues"." - Phil Wright, Head of Logistics, Greggs

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