Perhaps there is the question do we need a new warehouse or perhaps the decision has already been made. Congratulations, but now many steps need to be taken and many decisions need to be made. This all while still running the current operations in the current warehouse.

We can support with setting up this new warehouse. Some rough phases that exist and that we need to go through in order to setup a highly functional warehouse:

1. Goals and targets
The first phase is to very clearly define the expectations/requirements of this new warehouse. This includes taking a good look to what you expect the future will look like. Many assumptions will have to be made during this phase and it’s important to regularly check if these assumptions are still correct.

2. As-is
Documenting all current processes in flow charts. This will be required for double checking the to be processes to see if something is missing or things aren’t feasible?!??!?!?!

3. Data analysis
Number crunching time, this will form the basis of the next phases. Having reliable and complete data is highly important; the better the data the better the analysis the better the new processes. Tons of data will be required from ordering at your suppliers, to you customer orders and everything in between.

4. Define To Be
The fun phase; how should the new processes look like? The information father from the data analysis phase can support in this. Here we will start thinking about having manual or perhaps semi of complete automated processes.

5. Layout
Once the processes have been defined the question is how to fit them all together. This will first be done on a high level with a spot plan and will later on be defined with more details. This will form the basis for the next phase.

6. RFQ
The layout plan and all material requirements (like number of work stations, MHE, racking, toilets, etc) will be discussed with several contractors. The benefit of having the requirements clear up front is that it greatly helps in comparing the different contractors to one another.

7. Build
Finally, after all the calculating, brainstorming and planning the actual building starts. During this phase it’s important to keep on eye on things to make sure everything gets build as discussed. This time can also be used to start preparing for the move from the old to the new warehouse.

8. Use
Ramping up and for the first time seeing the processes in action, goose bumps. Getting a feel for the processes and steadily ramping them up in order to start benefiting all that hard work.

More information and lessons learned will become available in the knowledge database.