Layout of a Warehouse: a real case study

Space is a crucial element in every type of warehouse. Knowing how to utilize and optimize it to its fullest potential is essential for achieving efficiency, reducing unnecessary costs, and ensuring balanced operations. Poorly organized space can lead to congestion, longer handling times, and higher operational expenses, while effective space management can provide a competitive advantage by streamlining internal flows and supporting smoother production processes. Designing and setting up a new warehouse is therefore a delicate operation. The choices made at this stage will determine the long-term performance of the facility. An efficient layout not only reduces the time and costs associated with material handling but also improves safety, enhances productivity, and ensures that resources are used in the most rational way. However, despite its importance, warehouse layout design is a complex and challenging task. Identifying the most suitable layout is far from straightforward. The decision depends on a wide range of variables, including the type and variety of products to be stored, the specific operational requirements of the firm, and the physical and logistical constraints of the building. Balancing these aspects requires a structured approach that is able to capture both space allocation needs and handling efficiency. This study addresses these challenges in a real industrial case involving the storage of work-in-process goods used in the production of wood flooring. The case focuses on determining the optimal depth of storage racks in a multi-deep manual warehouse. The decision-making was modelled as a discrete optimization problem, solved using a genetic algorithm. The algorithm identified the optimal storage depth for each work-in-progress good, under space and time constraints required by the firm.