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[ TvastrOps Warehouse Standards ]

What a well-run warehouse gets right.

41 criteria in four parts, one for each Warehouse Audit. Every audit rates each criterion in its part with the evidence recorded, then ranks the fixes. Each criterion is either sourced to a recognized standard or marked as TvastrOps practice from US manufacturing and retail operations. Structure, fire and statutory compliance are referred to licensed specialists; we record what we observe and never certify it ourselves.

Part 1 · 8 criteria

Site & Building

Whether a building can carry the operation you plan to run in it, checked before you lease, buy or take it over.

Scored in the Warehouse Site Assessment (Pre-Lease) →
  1. SB-01

    Usable clear height under the lowest obstruction (beams, sprinklers, lights) supports the planned number of storage levels.

    Basis: TvastrOps practice; sprinkler clearances referred to a fire specialist (NBC 2016 Part 4)

  2. SB-02

    The column grid allows full rack bays and the aisle widths the planned equipment needs, without lost positions.

    Basis: TvastrOps practice

  3. SB-03

    Dock count and dock heights match the peak-hour truck arrival profile and the vehicle types used.

    Basis: TvastrOps practice

  4. SB-04

    Yard depth and approach roads let the largest vehicle turn, queue and dock without blocking public roads.

    Basis: TvastrOps practice

  5. SB-05

    Floor loading is documented and adequate for planned rack point loads, and floor flatness suits the planned equipment, to defined-movement classes where very narrow aisle trucks will run.

    Basis: Concrete Society TR34 (defined-movement floors); loading verified by a structural engineer

  6. SB-06

    Power supply is documented and sufficient for lighting, charging and planned equipment.

    Basis: TvastrOps practice

  7. SB-07

    Building approvals and fire clearances the owner can provide cover storage use.

    Basis: National Building Code of India 2016, Part 4 (storage occupancy, Group H); compliance confirmed by a licensed specialist

  8. SB-08

    The site leaves room for the growth in the business plan: expansion land, height or reconfiguration.

    Basis: TvastrOps practice

Part 2 · 15 criteria

Infrastructure

Whether the racking, docks, floors, routes and equipment you have are suitable and in condition for the operation you now run.

Scored in the Warehouse Infrastructure Audit →
  1. IN-01

    Racking is free of damage beyond acceptable limits, and any damage is recorded and classified.

    Basis: EN 15635 (application and maintenance of storage equipment)

  2. IN-02

    Each rack run shows a load notice that matches its current beam configuration.

    Basis: TvastrOps practice

  3. IN-03

    Racks are anchored, and upright protection is fitted at aisle ends and vehicle paths.

    Basis: TvastrOps practice

  4. IN-04

    Rack configuration is installed within design tolerances and clearances.

    Basis: EN 15620 (tolerances, deformations and clearances); design to EN 15512

  5. IN-05

    Aisles are kept clear, permanent aisles are marked, and powered equipment has enough clearance at docks, doorways and turns.

    Basis: OSHA 29 CFR 1910.176 (handling materials, general)

  6. IN-06

    Overhead clearance limits are signed.

    Basis: OSHA 29 CFR 1910.176

  7. IN-07

    Pedestrian and vehicle routes are separated and marked.

    Basis: TvastrOps practice; OSHA 29 CFR 1910.176 (marked aisles)

  8. IN-08

    Floors are free of damage that affects equipment or people, and are maintained.

    Basis: Factories Act 1948, s.32 (where the site is a factory); TvastrOps practice

  9. IN-09

    Lighting is adequate for the task in every working area.

    Basis: Factories Act 1948, s.17 (where the site is a factory); TvastrOps practice

  10. IN-10

    Docks (levelers, seals, lights, wheel chocks) work and suit today's vehicles.

    Basis: TvastrOps practice

  11. IN-11

    Fire equipment and exits are accessible and not blocked by stock.

    Basis: Factories Act 1948, s.38; NBC 2016 Part 4; sign-off by a fire specialist

  12. IN-12

    Where very narrow aisle (VNA) trucks run, aisle widths, truck guidance (rail or wire) and rack clearances match the truck maker's specification.

    Basis: EN 15620 (clearances); TvastrOps practice

  13. IN-13

    VNA and high-bay racking has an EHS review on record covering rack height, aisle access and pedestrian exclusion.

    Basis: TvastrOps practice

  14. IN-14

    Truck operators are trained and authorized for the truck types they drive, including VNA turret and man-up trucks.

    Basis: OSHA 29 CFR 1910.178 (powered industrial trucks, operator training); TvastrOps practice

  15. IN-15

    Pedestrians are kept out of VNA aisles while trucks operate, by barriers, signage or detection.

    Basis: TvastrOps practice

Part 3 · 10 criteria

Operations

Whether receiving, storage, picking, packing and dispatch run to a standard, with accurate stock and measured performance.

Scored in the Warehouse Operations Audit →
  1. OP-01

    Every process (receive, put away, pick, pack, dispatch) has a current SOP that matches what the floor actually does.

    Basis: TvastrOps practice

  2. OP-02

    Inbound goods are put away within the shift they arrive.

    Basis: TvastrOps practice

  3. OP-03

    Inventory accuracy is measured at location level through scheduled cycle counts.

    Basis: WERC DC Measures (inventory count accuracy by location)

  4. OP-04

    Every stock adjustment has a reason code and a named approver.

    Basis: TvastrOps practice

  5. OP-05

    Fast movers are slotted closest to dispatch and at working height.

    Basis: TvastrOps practice

  6. OP-06

    Orders are released in waves or batches matched to packing capacity.

    Basis: TvastrOps practice

  7. OP-07

    Core KPIs are tracked with fixed definitions: lines per labor hour, order picking accuracy and dock-to-stock time.

    Basis: WERC DC Measures (metric definitions)

  8. OP-08

    Damaged, returned and quarantined stock is held in marked areas and is visible in the system.

    Basis: TvastrOps practice

  9. OP-09

    Workplace organization and visual management (5S) are in place and sustained.

    Basis: Lean Six Sigma (5S); TvastrOps practice

  10. OP-10

    Shortages and errors are logged with a cause, and repeat causes are closed out.

    Basis: Lean Six Sigma DMAIC (Control); TvastrOps practice

Part 4 · 8 criteria

Capacity & Utilization

How hard the storage, docks and equipment you already have are working against real demand, and how much headroom is left.

Scored in the Warehouse Capacity & Utilization Audit →
  1. CU-01

    Occupied versus available positions are known by zone, location type and level, for the current week.

    Basis: TvastrOps practice; WERC DC Measures (warehouse capacity used)

  2. CU-02

    Beam heights match today's pallet heights, and the vertical cube is used.

    Basis: TvastrOps practice

  3. CU-03

    Location types match item velocity and size, with no fast movers holding full pallet positions slow movers need.

    Basis: TvastrOps practice

  4. CU-04

    Dock utilization is measured by hour and door, and peaks stay within dock capacity.

    Basis: TvastrOps practice

  5. CU-05

    Forklift and MHE utilization, availability and idle time are measured.

    Basis: TvastrOps practice

  6. CU-06

    Travel distance for representative tasks is measured and reduced.

    Basis: TvastrOps practice

  7. CU-07

    Capacity headroom is known against average and peak demand, and projected at forecast volumes.

    Basis: TvastrOps practice; WERC DC Measures (average and peak capacity used)

  8. CU-08

    Aisle congestion and crossing points are identified and designed out.

    Basis: TvastrOps practice

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