Engineering Warehouse Layout Redesign: Integration of Class-Based Storage Methods and GMP Principles

Abstract

General Background Space limitations and irregular item arrangements in industrial engineering warehouses frequently hinder operational efficiency and increase the risk of material damage. Specific Background This study addresses the layout redesign of the engineering warehouse at PT. XYZ by integrating Class-Based Storage (CBS) methods, Good Manufacturing Practice (GMP) principles, and BLOCPLAN-90 software evaluation. Knowledge Gap Existing storage configurations lack optimal grouping based on item movement frequency, leading to inefficient space utilization and prolonged material handling times. Aims This study aims to redesign the warehouse layout to optimize space usage and minimize total material handling activity time. Results The analysis selected the 17th proposed layout, which successfully improved space efficiency from 93% to 90% and reduced total material handling time from 146.80 minutes to 143.98 minutes. Novelty This work introduces an integrated warehouse optimization framework combining CBS zoning for 14,212 component types, BLOCPLAN spatial iteration, and GMP 5S controls. Implications Systematic warehouse layout restructuring enhances operational workflow, reduces retrieval time, and supports sustainable inventory management. Key Findings Highlights Class-Based Storage grouping effectively organizes 14,212 component types according to their movement frequency. The 17th proposed layout achieves optimal spatial configuration with an adjacency score of 0.72 and a rel-dist score of 929. Integrating GMP principles and 5S controls successfully sustains warehouse neatness, cleanliness, and operational efficiency. Keywords Warehouse Layout, Class-Based Storage, Blocplan, Good Manufacturing Practice, 5s