Advanced Tips for Managing and Optimizing Warehouse Layout for Mixed Product Sizes
In the building materials industry, no two SKUs are alike. From tiny fasteners to 20-foot steel beams, managing a warehouse filled with mixed product sizes demands more than just storage—it requires strategic layout design, precise inventory logic, and ERP-backed execution.
Here are advanced tips to help you build a warehouse layout that handles size diversity, speeds up operations, and maximizes efficiency—no matter how complex your SKU mix.
Understand the Core Problem: One Warehouse, Infinite Variability
Unlike standard eCommerce or retail operations, building materials distributors handle:
Small, high-turnover items (e.g., nails, screws, adhesives)
Bulk, heavy goods (e.g., cement bags, bricks, tile pallets)
Long-length or oversized materials (e.g., PVC pipe, rebar, lumber)
Fragile or condition-sensitive SKUs (e.g., insulation, drywall)
This variety puts pressure on layout, flow, and safety—especially when manual systems can’t keep up with movement, spacing, and tracking.
Tip 1: Segment by Size and Movement Rate, Not Just Product Type
A common mistake is organizing by product category—when what matters more is:
How often a product moves
How much space it takes up
How it’s handled (pallet jack, forklift, manually)
Use your ERP to generate heatmaps and turnover reports, then rezone your warehouse accordingly:
Fast-moving, small parts: Near packing/shipping
Bulk pallets: On the floor or low-rack access
Oversized goods: Designated long-load lanes or cantilever storage
Specialty materials: Segregated, climate-controlled zones
Tip 2: Digitally Assign Bin Locations in ERP
Your ERP should let you assign bin or rack locations based on dimensions and handling logic, such as:
Maximum height
Weight per level
Accessibility for forklifts or cranes
Weather exposure (for partially outdoor yards)
With this setup, your warehouse team can quickly identify the best-fit location for new stock, and your system can recommend placement during receiving.
Tip 3: Optimize Picking Routes for Mixed Inventory
When orders include mixed product types (e.g., bags of cement + steel beams + screws), your team may end up doubling back or making multiple trips.
Modern ERP systems help by:
Creating zone-based picking lists
Suggesting the most efficient path through mixed-storage zones
Flagging materials that require special equipment or assistance
Advanced setups even allow you to batch similar orders together for faster loading.
Tip 4: Use Dedicated Zones for Oversized Items
Long, bulky, or heavy items shouldn’t block normal workflows. Dedicate a portion of your warehouse or yard to:
Wide-aisle storage for forklifts
Vertical cantilever racking for pipes, timber, or rods
Ground-level staging areas for pre-loading large SKUs
Ensure these areas are mapped in your ERP and excluded from small-parts picking routes.
Tip 5: Plan for Seasonal Flexibility
Your layout should adjust with seasonal product demand. Use historical ERP data to reassign staging areas or picking lanes for:
Increased cement movement during summer
More insulation staging in winter
Regional material differences across yard locations
Modular layout design paired with dynamic ERP zone tagging gives you the flexibility to shift with demand.
Final Thoughts
Optimizing a warehouse layout for mixed product sizes isn’t just about space—it’s about visibility, flow, and smart system logic. With a building-materials-specific ERP, you can:
Automate picking logic
Balance accessibility and safety
Dynamically assign space
Reduce picking time and inventory errors
📦 Looking to redesign your warehouse layout for a more diverse product mix? Let’s build a scalable, ERP-driven blueprint that fits your operation.
