Implementation of a Layout Design to Improve Storage Processes in a Raw Material Warehouse

Abstract

This study analyzes the implementation of a layout design in a raw material warehouse with the aim of improving storage and order preparation processes. The project was developed through a diagnosis of the initial state, the application of the 5S methodology, the ABC inventory classification, and the redesign of the distribution using Systematic Layout Planning (SLP) principles. Information was collected through interviews with the personnel involved, process observations, a 5S checklist, inventory analysis, and before-and-after measurements. For order preparation, the project reports ten observations over ten working days in the initial and post-intervention measurement tables. The mean order-preparation time decreased from 105 ± 10.0 minutes (n=10) to 40 ± 5.7 minutes (n=10), equivalent to a 61.9% reduction. Travel distance decreased from 71 to 45 meters, corresponding to a 36.6% decrease; these distances are reported as total process-route values in the process-analysis diagrams, and repeated distance observations were not provided in the source project. The 5S order-and-cleanliness score increased from 23% to 94% using a weighted nine-item checklist. The new layout incorporated demarcated zones, storage systems, and material positioning based on inventory value and turnover. The results describe the changes observed in the analyzed warehouse and should not be interpreted as evidence that the same magnitude of improvement will occur in other warehouse environments.