SCL Course: Warehouse / Distribution Center Layout

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Do you work with problems involving the use of material handling equipment in plants, warehouses and other commercial enterprises? All techniques presented are field-proven and derived from successful implementation. Case exercises are adapted from real situations and projects.


  • Industrial engineers and systems analysts
  • Warehouse supervisors and team leaders
  • Warehouse/distribution center managers
  • Logistics and supply chain planners
  • Planning teams for new or expanded facilities
  • Leaders of supply chain and lean initiatives


  • Case Exercise in Layout Planning
    • Six-step simplified planning procedure, charts, and diagrams
  • Systematic Layout Planning (SLP)
    • Four phases of every layout project
    • Systematic planning procedures, gathering and projecting data
  • Profiling and Inventory Analysis
    • Activity, order, and inventory profiles
    • Zoning and picking methods
    • Matching your methods to inventory levels and flows
    • Storage capacity calculations
  • Handling and Storing Equipment (Simple and Complex)
    • Unit load handling, storage, case, and item picking
  • Case Exercises in Methods Selection (storage, handling, order picking)
  • Layouts and Flow Patterns
    • Commodity, activity, and other storage zones
    • Basic flow patterns and their benefits
    • Charting your operations and defi ning your activity-areas
  • Flow of Materials Analysis
    • Ways to measure and visualize material flow
    • Quantified flow diagram and flow analysis
    • Combining flow and other-than flow relationships
  • Case Exercise in Establishing and Estimating Space Requirements
    • Shorter and longer range space projections
    • Balancing space required to space available
  • Case Exercise in Warehouse Layout and Materials Handling
    • Adjusting for physical features of the facility
    • Rack and aisle orientations
  • Material Handling Methods
  • Evaluation of Alternative Plans - Costs and Intangibles
  • Detailed Layouts
    • Rack storage and dock areas, shelving arrangements, and slotting
    • Application of SLP to equipment layout
  • Case Problem in Distribution Center Planning
    • Developing a preliminary arrangement and improving the plan
    • Integrating storage and handling methods
    • Responding to changing and unforeseen requirements
  • Organizing Your Layout Project
    • Recap of phases, steps, and planning documents
    • Working forms and templates for your next project


Participants receive a course notebook.


H. Lee Hales is President of Richard Muther & Associates. Lee is the author and co-author of several books on industrial planning, including: Systematic Planning of Industrial Facilities (with Richard Muther) and Computer-Aided Facilities Planning.As a materials and distribution manager, Mr. Hales planned, set up and managed a network of distribution facilities in the oil field equipment industry. In addition to warehousing, he managed purchasing, transportation, and information systems.As a consultant, Mr. Hales has assisted on a wide range of projects in the US, Asia, Europe, and South America. His clients have included: AGCO, Avon, Caterpillar, Clorox, Motorola, Nokia, General Motors, Ford, Coca-Cola, Fastenal, The Container Store, The Teaching Company, WW Grainger, Delta Air Lines, Glaxo, Philips, Textron, and many others.Mr. Hales is a Senior Member of the Institute of Industrial Engineers, and past Director of the Facilities Planning & Design Division. Mr. Hales has also served on the College-Industry Council for Material Handling Education, sponsored by the Material Handling Institute. He received B.A. and M.A. degrees from the University of Kansas and holds an M.S. in Management from the Sloan School, Massachusetts Institute of Technology.


  • Workflow Status: Published
  • Created By: Anita Race
  • Created: 04/22/2014
  • Modified By: Fletcher Moore
  • Modified: 10/07/2016


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