Project Overview

The project focused on redesigning a warehouse layout to improve space utilization, picking efficiency, and automation readiness. Using AutoCAD and operational data, we developed a detailed 2D and 3D layout plan integrating Kardex storage machines to optimize vertical space usage.

Problem Statement

Manual storage systems and traditional shelving layouts limited capacity and efficiency. The warehouse experienced long travel distances, inconsistent picking times, and poor use of vertical volume. There was a need for a data-driven redesign that would quantify the impact of automation and support future scalability.

Solution

We performed a data-driven warehouse analysis using SKU turnover rates, picking frequency, and layout simulation to identify inefficiencies.
Based on the insights, we created a new AutoCAD layout incorporating Kardex vertical lift modules (VLMs) and automated zones for small parts storage.
Key steps included:

• Designing multiple layout concepts and validating them through AutoCAD simulations.

• Performing cost estimation and ROI calculations for Kardex system integration.

• Creating a phased implementation roadmap to minimize downtime.

Result

• 35% improvement in space efficiency through vertical storage design.

• Precise cost model supporting investment decisions.

• Implementation plan visualized in AutoCAD for smooth real-world rollout.