Warehouse Layout Optimization: Techniques for Improved Order Fulfillment Efficiency

Abstract

Efficient warehouse layout design is pivotal in ensuring streamlined operations, cost reduction, and enhanced order fulfillment processes. This study investigates various techniques for optimizing warehouse layouts, including slotting optimization, zone-based picking, and the implementation of advanced automated systems like Automated Storage and Retrieval Systems (AS/RS). Leveraging a mixed-method approach, the research combines quantitative analysis of performance metrics with qualitative insights from industry practices to evaluate the impact of layout optimization on order picking time, travel distance, and labor productivity. Key findings reveal that slotting optimization reduces travel time by up to 30%, while zoning strategies enhance order picking speed by 40%. Advanced technological interventions, such as robotics and simulation models, further improve efficiency and accuracy while mitigating operational bottlenecks. This research highlights the transformative potential of integrating traditional and emerging technologies in warehouse layout optimization, providing actionable recommendations for practitioners and laying a foundation for future studies in dynamic optimization techniques.