The ongoing disruptions in many supply chains are leading to higher stockpiling – and thus to a constantly growing need for storage capacity. This can be achieved by new construction and expansion of storage areas. However, a more economical way is to make better usage of existing storage areas by structuring them in such a way that they can be optimally loaded.

W2MO capacity optimization allows for the straightforward optimization of storage space sizes. By leveraging packing algorithms that encompass all pertinent product characteristics, including dimensions, weight, stacking factors, and compressibility, the optimal size for each product bin or area can be determined. Regardless of whether the storage setup is for a single product or a mixed product, or if there are restrictions on the separation of batches, W2MO will support with creating the optimal sizing for all setups

This dimensioning can be applied for bulk areas as well as for rack structures. Putting savings into practice in a bulk warehouse (regardless whether inside or outside) is very simple: adapt floor markings and define storage locations differently in the WMS. The assignments created during the optimization can be used to set up your product placement – read more about this in our Advanced Slotting section.

The warehouse capacity optimization process begins with the calculation of optimal storage sizes based on product properties, stock data, and demand behavior and further constraints. In the second step, these optimally sized storage needs are placed in the warehouse in an efficient manner to maximize the effective storage capacity.

Considering minimaile aisle widths, block areas as well as process retictions the optimal set up of your warehouse will be designed. When using the W2MO warehouse capacity optimization, there is an overall increase in net storage capacity of 6 – 25%. In a medium warehouse with e.g. 5,000 storage locations this means over 1,000 additional storage spaces. Based on the typical “overnight costs” of a pallet of €3, this results in potential cost savings of € 3,000 per day – and over € 1 million per year!

After having created a new structure, the W2MO Digital Twin can be used to understand the effects of this structure on the processes. Use simulation and evaluation options to get insights to resulting efforts, bottle neck and congestion situations. Optimize your structure even further to avoid blockages and re-run the simulation to see the effects – all in one tool. Read more about simulation in our simulation section.

The simulation can also be used to determine the best transportation modes in your new structure. Regardless whether you want to see the effects of a 2-fold forklift vs. the usage of a 4-fold one or if you want to determine if an AMR could be useful for you, just change some settings in the Digital Twin and you can see the effects on efforts and capacity.