Warehousing Capacity Planning Checklist
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Demand Forecasting & Projections
Assess current and future demand to understand storage needs. This includes analyzing historical data, seasonality, and projected growth.
Average Daily Order Volume (Current)
Projected Order Volume Growth Rate (Annual, %)
Start Date for Demand Forecast
End Date for Demand Forecast
Describe Key Factors Influencing Demand (e.g., seasonality, promotions, market trends)
Peak Season Order Volume Multiplier (Compared to average)
Upload Historical Sales Data (CSV/Excel)
Primary Forecasting Method Used
Current Warehouse Assessment
Evaluate current warehouse space utilization, storage methods, and operational efficiency. Identify bottlenecks and inefficiencies.
Total Usable Square Footage (sq ft)
Current Storage Utilization (%)
Description of Current Storage Methods (Racking, Pallet Stacking, etc.)
Number of Pallet Locations
Number of Bulk Storage Locations
Current Challenges/Bottlenecks (Select all that apply)
Detailed observations/notes on current warehouse layout and operations.
Warehouse Layout Diagram/Map (if available)
Storage Requirements Analysis
Determine the specific storage needs based on product characteristics (size, weight, fragility, temperature requirements, etc.) and order profiles.
Average Unit Size (LxWxH in inches)
Average Unit Weight (lbs)
Average Pallet Size (LxWxH in inches)
Average Pallet Weight (lbs)
Storage Type Required (e.g., Temperature Controlled, Dry)
Special Handling Requirements
Notes on specific product or category storage requirements
Units/Pallets per SKU (Estimated)
Space Optimization & Utilization
Explore opportunities to maximize existing warehouse space through improved layout, racking, automation, and storage techniques.
Current Utilization Rate (%)
Detailed Description of Current Storage Methods (e.g., Pallet racking, flow rack, shelving)
Which racking/storage system modifications are being considered?
Potential Space Gain (sq ft) from Layout Optimization
Priority for Vertical Space Utilization?
Specific Constraints/Limitations to Space Optimization (e.g., structural limitations, safety regulations)
Current Warehouse Layout Diagram (for reference)
Future Growth & Scalability
Plan for future growth and expansion needs, considering potential increases in volume, product lines, and order complexity.
Projected Annual Growth Rate (Volume)
Expected Increase in SKU Count (Next 3 Years)
Describe Potential New Product Lines & Their Storage Requirements
Estimated Date of Next Major Capacity Review
Forecasted Peak Season Volume Increase (%)
Potential Expansion Strategies
Required Additional Pallet Positions (Estimate)
Describe any anticipated changes in product size or packaging
Risk Assessment & Contingency Planning
Identify potential risks (e.g., disruptions to supply chain, unexpected demand spikes) and develop contingency plans to ensure capacity is available.
Maximum Acceptable Stockout Duration (Days)
Describe potential supply chain disruptions that could impact warehouse capacity.
Identify potential risks affecting capacity (select all that apply)
Estimated Lead Time for Temporary Storage Solutions (Days)
Date of Last Risk Assessment Review
Outline contingency plan for a major equipment failure (e.g., primary racking collapse)
Primary Contingency Storage Option (if needed)
Technology & Automation
Evaluate the potential of warehouse management systems (WMS), automated storage and retrieval systems (AS/RS), and other technologies to improve capacity utilization and efficiency.
Current WMS in Use?
Current Warehouse Density (CBM/sqm)
Potential Automation Technologies to Investigate
Initial Assessment of Potential ROI for Automation
Estimated Automation Investment Budget (USD)
Target Date for Automation Implementation (if applicable)
Cost Analysis & Budgeting
Analyze the costs associated with different capacity planning options, including construction, leasing, automation, and labor. Develop a budget for capacity upgrades.
Estimated Cost of New Warehouse Construction (if applicable)
Estimated Cost of Warehouse Lease Expansion (if applicable)
Cost of New Racking Systems
Cost of Warehouse Management System (WMS) Implementation (if applicable)
Estimated Annual Labor Costs (Current & Projected)
Cost of Automation Equipment (e.g., conveyors, sorters)
Utility Costs (Current & Projected)
Assumptions Underlying Cost Estimates
Location & Layout Considerations
Evaluate the suitability of warehouse location for accessibility, transportation costs, and labor availability. Optimize the internal layout for efficient flow.
Current Dock Door Count
Desired Dock Door Count (Future)
Proximity to Major Transportation Routes
Description of Current Warehouse Layout
Is the current layout conducive to efficient product flow?
Average Travel Distance per Pick (estimated)
Warehouse Location (GPS Coordinates)
Notes on future layout changes
Labor & Workforce Planning
Estimate labor requirements based on planned capacity and operational efficiency. Develop a workforce plan to support capacity needs.
Current Warehouse Labor Capacity (Orders/Day)
Projected Increase in Order Volume (Orders/Day)
Estimated Labor Hours Required for Projected Volume
Current Average Labor Cost Per Hour
Number of Warehouse Associates Currently Employed
Required Number of New Warehouse Associates
Training Requirements for New Associates?
Date New Hires are Expected to Join
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