Slotting
Also known as: Warehouse Slotting, Product Slotting, Slot Optimization
Definition
Slotting is the process of organizing warehouse inventory in optimal locations based on product velocity, size, weight, and picking patterns. Good slotting reduces travel time, improves productivity, and creates safer working conditions.
Slotting Objectives
- Minimize travel - Fast movers near packing stations
- Optimize ergonomics - Heavy items at waist height
- Maximize space - Right-sized locations for each SKU
- Reduce congestion - Spread popular items to avoid bottlenecks
- Support pick accuracy - Similar items separated
Slotting Factors
| Factor | Slotting Decision |
|---|---|
| Velocity (picks/day) | High velocity = prime location |
| Product size | Match slot size to product |
| Weight | Heavy items at ergonomic height |
| Pick quantity | Bulk picks in bulk locations |
| Affinity | Products ordered together placed near each other |
| Special handling | Hazmat, refrigerated, secure |
Zone Types
Golden Zone
- Eye to waist level
- Easiest access
- Reserved for highest velocity items
- Most ergonomic picking
Reserve Storage
- Upper levels, bulk areas
- Lower velocity items
- Replenishment source for pick locations
Floor Level
- Heavy items
- Full-case picks
- Pallet picks
Slotting Strategies
- ABC analysis - A items in best locations
- Velocity-based - Picks per day drives placement
- Family grouping - Related items together
- Random slotting - System assigns available slots
- Fixed slotting - Products always in same location
Reslotting
Slotting isn’t one-time—seasonal changes and new products require regular updates:
- Frequency - Quarterly or seasonally
- Triggers - New products, velocity changes, layout changes
- Process - Analyze data, plan moves, execute during low activity
Impact of Good Slotting
- 10-30% improvement in picking productivity
- Reduced worker fatigue and injuries
- Better space utilization
- Lower error rates
- Faster order fulfillment
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