Whether you’re optimising your existing warehouse operations or preparing for growth, this guide offers the tips you need to transform your warehouse into a faster, safer, and more productive environment.
Inventory & Stock Management
- Use space effectively:
Use totes and bins to organise stock. Make full use of shelf height and depth (on both sides if possible). Narrower aisles save space, but ensure there’s still room for equipment or two people to pass. Keep aisles clear for safety and efficiency. - Organise stock smartly:
Place fast-selling items in easy-to-reach locations. Move slower stock elsewhere. Group items by type, size or brand to make picking and receiving easier. - Design for flexibility:
Plan your layout to handle daily restocking and seasonal changes. A flexible system saves time and keeps operations running smoothly. - Protect your stock:
Keep shelves tidy and “faced off” to stop items falling, getting crushed, or snagged on equipment. Regularly cycle count and check stock to spot issues early and prevent theft. Store high-value items where they can be monitored by managers or CCTV. - Receiving and returns:
Check all incoming items carefully to avoid damaged or incorrect stock entering inventory. Treat returned stock as valuable and process it like new stock.
Order Processing & Picking
- Efficient layout:
Your warehouse layout should support fast, accurate order picking. A “snake” picking pattern (moving through aisles in order) can reduce travel time by up to 30%. - Picking methods:
- By aisle or zone: Teams focus on specific areas, ideal for fast-moving, delicate, or high-priority items. This supports live picklists and a steady workflow with timed spacing between pickers.
- By order: Less efficient, but useful for large or urgent customer orders, especially those requiring machinery.
- Wave picking: Pick several orders at the same time, then assemble them for dispatch. Good for high volumes.
- By aisle or zone: Teams focus on specific areas, ideal for fast-moving, delicate, or high-priority items. This supports live picklists and a steady workflow with timed spacing between pickers.
Staffing & Resources
- Training is essential:
Ensure all staff are properly trained so processes are followed correctly. A good Warehouse Management System (WMS), like WaveOMS, should be easy to use with minimal training needed. - Monitor and support performance:
Hold regular reviews to track KPIs, identify staff strengths, and assign roles for maximum efficiency. - Reduce inefficiencies:
Cutting wasted time lowers labour costs and reduces overtime. Encourage staff to work productively earlier in the day to make afternoons less pressured and more efficient.
Technology & Equipment
Maintain equipment:
Carry out regular monthly equipment checks. Use a sign-in/out system to track usage and damage, and to avoid loss of tools or devices.
Go paperless:
Paper-based systems are slow, expensive and prone to errors. A digital system improves accuracy, saves time, and makes it easier to gather data, track stock, and report on performance.
Use a WMS (Warehouse Management System):
A Warehouse Management System helps manage inventory, create reports, monitor KPIs, and run operations efficiently with fewer resources. WaveOMS offer a suite of warehouse management system and order fulfillment management systems to help you transform your warehouse.
Use barcoding:
Barcoded products and handheld scanners improve accuracy, stock tracking, and traceability. They also reduce errors during picking and packing.