Running a warehouse isn’t just about storing products. It’s about using space wisely, moving items quickly, and keeping costs low. But many companies make a big mistake—they ignore the slotting strategy.
Bad slotting leads to wasted space, longer picking times, and higher labor costs. Over time, these problems add up, eating into profits. The good news? Smart warehouse planning can fix this. With the right approach, you can use space better, speed up order fulfillment, and cut costs.
How Bad Slotting Hurts Your Business
Many businesses don’t realize how much poor slotting costs them. If products aren’t stored in the right places, everything slows down. Here’s what happens when slotting goes wrong:
1. Wasted Warehouse Space
Warehouses have limited room. If items are not stored correctly, shelves get overcrowded while other areas stay empty. This leads to:
● Overfilled racks with wasted gaps in between
● Underused vertical space that could store more products
● Messy aisles that slow down workers
Bad slotting forces companies to rent extra storage when they don’t really need it. A better layout helps fit more products in the same space.
2. Higher Labor Costs
Workers waste time searching for misplaced items. If products are not in the best spots, it leads to:
● Longer pick routes
● More walking and lifting
● Increased order mistakes
Every extra minute a worker spends searching for a product costs money. Over time, these delays add up to thousands in extra wages.
3. Slower Order Fulfillment
Customers expect fast shipping. Bad slotting makes it hard to meet deadlines because:
● Pickers take longer to find items
● Packing stations get backed up
● Orders ship late
A slow warehouse hurts customer satisfaction. Faster picking means happier customers and fewer returns.
4. More Equipment Wear and Tear
If forklifts and carts have to travel longer distances, they wear out faster. This causes:
● More fuel or battery use
● Frequent breakdowns
● Higher repair costs
Shorter travel paths reduce strain on equipment and lower maintenance expenses.
5. Poor Inventory Control
Bad slotting also makes stock management harder. It can lead to:
● Overstocking slow-moving items
● Running out of fast-sellers
● Damaged goods due to poor placement
Keeping high-demand products in the wrong spots can cause delays and lost sales.
Smart Slotting Strategies That Work
The best warehouses don’t just store products—they organize them efficiently. Here are some slotting techniques to improve speed and cut costs.
1. Store Items Based on Demand
Products should be placed according to how often they are picked. This method is called ABC slotting:
● A-items (fastest sellers) → Near packing stations for quick access
● B-items (moderate movers) → Slightly further but still easy to reach
● C-items (slow movers) → Stored in less prime areas
This reduces travel time and speeds up picking.
2. Organize by Size and Weight
Heavy products should be on lower shelves to prevent lifting injuries. Lighter items can go higher up. This makes picking faster and safer.
3. Adjust for Seasonal Changes
Some products sell faster at certain times of the year. Adjusting slotting for seasonal demand means:
● Holiday products move up front in peak seasons
● Slow movers shift to the back during off-seasons
This keeps operations running smoothly all year.
4. Reduce Walking Distance
Workers should take the shortest path to pick orders. Warehouses can improve routes by:
● Grouping frequently ordered items together
● Creating one-way pick paths to prevent congestion
● Placing high-demand products near packing stations
Less walking means faster orders and lower labor costs.
5. Use Technology to Improve Slotting
Modern tools can make slotting even better:
● Warehouse Management Systems (WMS) track inventory and suggest better storage locations.
● Pick-to-Light and Voice Picking guide workers to the right items, reducing mistakes.
● Automated Guided Vehicles (AGVs) move products with precision, cutting down on manual labor.
Using data and automation helps warehouses stay efficient and profitable.
Better Slotting = More Profits
A poor slotting strategy wastes time, space, and money. Fixing it leads to:
● Faster order fulfillment
● Lower labor and equipment costs
● Better inventory control
Investing in Warehouse Strategic Planning Services helps businesses save thousands in unnecessary expenses while improving efficiency.
How JEC Consulting Services Can Help
At JEC Consulting Services, we specialize in warehouse optimization consulting. Our team finds and fixes slotting problems so your business runs smoothly.
What We Offer:
● Warehouse layout analysis to use space better
● Customized slotting plans based on demand and product type
● Technology integration for smarter inventory management
● Process improvements to speed up order fulfillment
Stop wasting space and losing profits. Contact JEC Consulting Services today for a Warehouse Slotting Assessment and start saving now!
