Facility layout & space allocation
Establish the usable building envelope, columns, clear heights, fixed services and operating adjacencies. Allocate receiving, reserve storage, forward picking, packing, kitting and dispatch space against demand.
← Warehouse Design & Optimization
Warehouse Layout Design
Physical and functional warehouse design, from storage requirements to an implementable layout.
Congested storage, difficult access, growing inventory, or an upcoming expansion or relocation. We agree the operating requirements, input data and decision criteria before developing recommendations.
On site in Hyderabad, across Telangana and India. All our services in Hyderabad →
- Rack configuration & usable capacity
- Aisle planning & MHE compatibility
- Receiving, picking, kitting & dispatch
- Master planning & phased reconfiguration
Engineering preview / illustrative drawing
Explore the operational design.
Inspect layout alternatives, material movement and operating controls. Interactive tools load as you approach this section; the service scope and deliverables remain available below.
ILLUSTRATIVE GEOMETRY · NOT A CLIENT WAREHOUSE
Service overview
Design the physical operation.
For a new facility, expansion or live re-layout, we compare storage configurations and space requirements, calculate usable capacity and document the chosen arrangement. Conceptual master planning establishes functional zones and growth allowances; architectural, structural and statutory design remain with appropriately qualified professionals.
We develop the physical arrangement of a warehouse around its inventory, load units, order profile and working methods. The design connects storage positions, operating zones and material-handling access rather than treating each area as a separate floor-space allocation.
Performance modeling is covered by Warehouse Simulation & Digital TwinB1 / Scope of work
Physical & functional design scope.
We agree the areas, data requirements and deliverables during scoping. The activities below define the service’s technical focus.
Docks, receiving & dispatch
Plan dock positions, inbound checks, staging lanes and dispatch consolidation around arrival profiles and cut-offs. Connect yard-to-dock interfaces with internal material movement.
Capacity, expansion & drawings
Calculate usable positions by zone and configuration, with occupancy assumptions and growth allowances. Prepare layout alternatives, engineering drawings and phased reconfiguration or relocation recommendations.
DE-02 / Technical explanation
Storage systems & rack configuration
Compare selective, block and other storage arrangements against SKU dimensions, pallet profiles, stockholding and access needs. Define rack bays, levels, load units and functional requirements for supplier review.
DE-03 / Technical explanation
Aisles & equipment compatibility
Check aisle widths, turning space, lift height and access against the selected MHE. Evaluate narrow aisle and very narrow aisle options with supplier turning envelopes, floor requirements and guidance constraints.
DE-04 / Technical explanation
Flow, picking & kitting zones
Position fast-moving items and workstations to reduce avoidable travel and crossing flows. Develop replenishment access, picking paths, kit preparation and interfaces with production.
Technical approach
From inputs to an operating decision.
Floor observation and operating data establish the basis; review and verification close the loop.
- 01
Establish the design basis
Review building drawings, SKU dimensions, inventory, volumes, equipment and growth assumptions; confirm critical dimensions on site.
- 02
Develop layout alternatives
Size storage and work zones, configure rack blocks, check access and map the movement between functions.
- 03
Compare & resolve trade-offs
Review capacity, travel, equipment access and implementation constraints with operations and specialist suppliers.
- 04
Issue & sequence the design
Document the selected arrangement, capacity schedule and requirements; agree moves, dependencies and verification points.
Applications
When this work is useful.
Typical operating situations; these are not client case studies.
- Aisles and staging areas are congested and stock is stored wherever it fits.
- Inventory is growing and you need to know how long the building will last.
- You are planning an expansion, a new building or a relocation.
- Access to frequently used items is slow or unsafe.
Engineering outputs
What you receive.
Working documents for decisions, supplier discussions and the change on the floor. The scope is agreed during discovery.
Layout alternatives
Storage and staging requirements, access and handling trade-offs in an agreed drawing set.Capacity & aisle schedule
Usable storage positions, rack configurations, clearances and handling access, with calculation assumptions stated.Equipment recommendations
Storage and handling requirements to evaluate with specialist suppliers.Phased implementation plan
Move windows, temporary locations, owners and release checks for the live operation.How we track results
Verification measures.
Key measures are defined around the warehouse and the change being tested.
Storage utilization
How much usable storage is occupied, by zone and storage type.
Measurement method
Occupied usable locations ÷ available usable locations; compare normal and peak demand.
Travel distance
How layout and working methods affect movement.
Measurement method
Measure representative routes and item mixes on the floor; validate any diagram scale.
Peak throughput
The output the operation can handle under peak conditions.
Measurement method
Record completed work per period alongside queues, staffing and the order profile.
Scope, measurement methods and improvement targets are agreed during assessment. Demo outputs are not measured client results.
[ Questions buyers ask ]
Common questions
How can we fit more pallets without moving to a bigger building?
Start with the space you have: re-slot fast movers, match beam heights to today's pallets, use the height under the roof, and test narrower aisles where your equipment allows. On a program before TvastrOps, a redesigned 31,000 sq ft warehouse needed 40% less projected space, tested in simulation before anything was built.
How long does a warehouse layout design take?
The first layout option comes 7 working days after the site walk, once the data we ask for is in. The full design depends on the site's size and how many alternatives you want compared, and we quote it phase by phase.
What data do you need to design a warehouse layout?
A site drawing with racks and docks, an item list with dimensions and units per pallet, the last three months of order lines by item, current stock by location, headcount and shift pattern by area, and photos of the busiest areas at peak.
Can you help us choose between selective racking, narrow aisle and VNA?
Yes. We compare storage systems against your item profile, throughput and building, including narrow and very narrow aisle feasibility, and support the racking and equipment specification. We are independent of suppliers, so the recommendation follows your operation, not a product catalog.
Do you stay for the move to the new layout?
Yes. We plan the change in phases so the warehouse keeps shipping, and stay on the floor through the move until the new layout holds on live shifts.
Start here
Let’s talk about
your warehouse.
Congested storage. Slow picking. Inventory mismatches. Lines waiting for parts. Tell us what’s not working, and we’ll identify where to start.