A worked warehouse slotting case study — current pick-path distance analysis, ABC velocity-based slotting logic, a redesigned aisle layout, and a before/after picks-per-hour comparison for a 10-aisle, 1,200-SKU distribution center.
The project brief: a regional parts distribution center picks manually from a 10-aisle shelving area, with roughly 1,200 SKUs slotted wherever a location happened to be open when each item was first received — arrival-order slotting with no relationship between a SKU's pick frequency and its distance from the shipping dock. This module replaces that with velocity-based (ABC) slotting derived from 12 months of real order-line history.
This module walks the whole redesign the way a real industrial engineer would: a worked current-state pick-path distance calculation, an 80/15/5 ABC pick-frequency classification, a redesigned aisle assignment that puts the highest-velocity items closest to the dock, and a before/after comparison of average travel distance, picking rate, and daily labor hours. The full worked numbers, before/after metrics table, and finished design reasoning are part of the unlocked module below.