How Warehouse Layout and Forklift Fleet Size Impact Productivity

Did you know that warehouse layout, floor conditions, and forklift fleet size can dramatically affect your operation’s productivity? If your facility struggles with congestion, inefficient workflows, or slow material handling, you’re not alone.

Common Warehouse Challenges

• Frequently handled products are separated due to size or storage requirements.
• Stock-Keeping Units (SKUs) have multiplied as your business grows.
• New product lines are stored wherever space is available.
• Aisles are congested with equipment, people, and product.
• Poor maintenance and floor conditions force detours and slow down forklifts.
• A small lift truck fleet requires more round trips on the same forklift.
• Poor lighting reduces travel and order-picking speeds.
• Inefficient warehouse layout creates dead-end aisles and workflow bottlenecks.

How to Reduce Forklift Travel Time and Boost Efficiency

1. Design an Efficient Warehouse Layout

Start by mapping your product flow. Draw arrows showing movement from receiving to storage to shipping. If arrows double back or move in opposite directions, you’ve found problem areas.

Key layout tips:

• Minimize travel distances between source and destination.
• Reduce forklift congestion in high-traffic zones.
• Improve access to product destinations.
• Eliminate bottlenecks for smoother workflows.

2. Consider Cross-Docking

What is cross-docking? It’s a process where products move directly from inbound delivery to outbound shipping with minimal storage time.

Best candidates for cross-docking:

• Barcoded products with high inventory carrying costs.
• Items with predictable demand and rapid turnover.

Implementing cross-docking can significantly reduce handling time and forklift travel.

3. Maximize Space Utilization

Use vertical racks or adopt a narrow aisle strategy to make better use of space. Add racks to side walls, over doors, and above thoroughfares. Improved space utilization reduces forklift travel time and boosts productivity.

4. Position Products for Efficiency

Re-slot SKUs based on activity:

• Place fast-moving items near their destinations.
• Store heavy or high-demand products at ground level.
• Balance storage and picking locations to avoid aisle congestion.
• Adjust inventory for seasonal or fluctuating demand.

Why It Matters

Optimizing your warehouse layout and forklift fleet strategy can:

• Reduce travel time.
• Improve order-picking speed.
• Lower operational costs.
• Increase overall productivity.