Reducing planning effort through 3D visualization of your warehouse
Professional warehouse planning forms the basis for efficient material flows, short throughput times and economical use of resources. It includes the structured analysis of existing warehouse processes, the determination of performance requirements, and the methodical design of warehouse structures and technologies. In view of growing product ranges, increasing automation possibilities and rising flexibility requirements, forward-looking and data-based warehouse planning is becoming increasingly important. By using modern planning and visualization tools, bottlenecks can be identified at an early stage, capacities can be optimally dimensioned and stable, future-proof warehouse processes can be created.
In warehouse planning, the planning process consists of several phases in which strategic goals are defined, requirements are specified, and appropriate measures for process optimization are developed. External experts can provide advisory support by conducting analyses, identifying optimization potential and assisting in the development of a viable warehouse concept. If required, coordination and negotiations with service providers or suppliers can also be undertaken to ensure that the planned logistics solution is economical, efficient and competitive in the long term.
In professional warehouse planning projects, the first step is a structured recording of the initial situation. This begins with an introductory meeting in which basic information, challenges and the goals of the warehouse planning are defined. This is usually followed by detailed project planning, including a schedule overview, role allocation and definition of strategic objectives.
The next step marks the start of the actual project phase, which includes comprehensive planning. This involves defining the roles involved, coordinating the timeline and setting the objectives for warehouse planning. This preparatory phase ensures that further steps are structured and transparent.
The subsequent actual-state analysis includes the detailed recording of existing warehouse processes on site. Functions, material flows and productivity indicators are systematically examined. Based on the data provided, key warehouse metrics are determined—such as stock levels, goods receipt volumes, picking processes, order volumes or goods issue figures. A visual analysis of intralogistics processes is also carried out. This phase additionally considers future developments of the company, planned growth, changes in the product range or changes in the sales structure. These insights are used to derive scenarios that reflect the specific need for action.
Based on the analyzed data, suitable warehouse systems and process variants are identified. A first material flow is sketched for these variants in order to compare possible solution approaches. This step helps to contrast different concepts and assess their potential impact on warehouse operations.
During the detailed development of the variants, the dimensions of each functional area—such as goods receipt, picking, storage and shipping—are finalized. Initial layouts of the variants are created and the warehouse type is evaluated along with the calculation of the related costs. In addition to the initial investment, ongoing costs for personnel, equipment and operations are also considered. After developing various variants, they are compared and evaluated based on jointly defined quality criteria and their economic viability. Following a comprehensive cost-benefit and utility analysis, you receive a final recommendation from logistics experts, enabling you to decide which warehouse planning variant should be implemented in your company.
As part of comprehensive warehouse planning, a detailed location analysis can be carried out. The aim of this analysis is to determine the geographically and economically optimal location for a warehouse. In addition to regulatory requirements, this process is based on the systematic evaluation of key criteria. The following questions serve as the basis for this location assessment and support informed decision-making.
Up to 25% of total logistics costs in many companies are associated with the construction and operation of a warehouse. Detailed warehouse planning helps identify key cost drivers within logistics processes and uncover potential savings.
Such planning includes, among other things, the design of new warehouse sites, the optimization of existing material flows and the analysis and consolidation of decentralized warehouse structures.
The associated service portfolio typically includes various areas of process analysis, structural design and economic evaluation of warehouse and logistics systems.
Planning your new central warehouse
Renewal, optimization and restructuring of your material flows
Independent and customized consulting throughout all development phases of your project
Cross-industry evaluation of the efficiency of your logistics processes
Development of new logistics and solution concepts
Feasibility studies in the context of innovative warehouse technologies and strategies
Virtual Reality.
When planning and designing complex internal logistics projects, the active involvement of all stakeholders plays a key role. Visualization, simulation and emulation solutions create transparent decision-making foundations. Specialized warehouse planning software is frequently used for this purpose, based on real material flow data. This allows processes to be clearly visualized and adjustments—such as in warehouse layout—can be evaluated quickly. Such methods increase planning reliability and support the economical design of logistics processes. The results can also be visualized using common virtual reality hardware or similar technologies. Models can be reused digitally or printed via 3D printers.
The use of virtual reality can measurably support decision-making in warehouse planning:
Simulation, emulation and visualization of logistics processes. All without a VR headset!
A typical optimization project includes the recording and analysis of logistics processes, the creation of a potential analysis and the development of an action plan. These steps help systematically identify improvement potential and derive structured recommendations for further development of the logistics system.
The receiving area should ideally be located directly next to the unloading docks and have suitable dimensions to handle all goods. Goods receipt and quality control are carried out here.
Optimal space utilization is essential here. In warehouse planning, turnover rates and products must be analyzed in detail. A distinction is made between three categories: low, medium and high turnover. The turnover rate strongly depends on the type of product or goods: For high-turnover, homogeneous goods, block storage or compact storage systems are suitable, especially when speed is more important than accessibility. Shelving systems are suitable for heterogeneous types of goods that tend to remain in storage longer.
The shipping area is critical in warehouse planning: It must be ensured that the order assembly and, if applicable, packaging areas interact with the shipping area. The shipping area should be large enough to accommodate all outbound lines and provide an additional consolidation area for unexpected demand peaks. A modern warehouse management system (WMS) supports order assembly and ensures highly efficient logistics workflows.
As a result of the study, it can be determined in advance that the potential of Logistics 4.0 is far from being fully utilized. The EPG survey reveals the field of tension in which companies are currently operating.
Do you have any questions? We are happy to assist you! If you would like to learn more about our holistic and manufacturer-independent warehouse planning, feel free to reach out to us! Our logistics experts are here to help you.
EPG Consulting is officially one of Germany’s top logistics consulting firms.