Levels Involved in the process of warehouse storage

What is warehouse storage and why is it important?

The process of storing products in warehouses and logistics facilities is known as Warehouse storage. Its job is to keep a consistent supply of commodities on the market in order to bridge the gap between producers' supply capability and Consumer Demand. It is also critical for ensuring product quality and value in warehouses and logistics management centers. With the introduction of frozen and refrigerated warehouses, for example, the storage function for fresh fish, vegetables, and fruits has vastly improved. Distribution centers (DC), transfer centers (TC), and process distribution centers are all important logistical sites in storage (PDC).

Warehouses have played an important role in the seamless operation of the supply chain for many years. Manufacturers, importers, exporters, wholesalers, transportation companies, e-commerce companies, and others all use warehouses. Warehouses perform the critical job of keeping goods while also providing services that allow for improved inventory control from the moment they are manufactured to the time they reach the consumer market.

Warehouses help firms maintain optimum inventory management by acting as a centralized area where commodities may be picked, distributed, and transported to intended consumption centers. Warehouses also benefit firms financially since efficient storage and logistics management cut transportation, shipping, and order delivery costs, among other things.

Warehouse storage is a critical component of the supply chain that acts as a buffer between demand and supply. There are various types of warehouses, each with its own set of functions.

Types of Warehouse Storage Systems

Pallet racking system: This is the most commonly used warehouse storage system. Pallets are piled in horizontal rows with numerous levels on racks. Pallet racking systems are used in warehouses because they are simple to install and organize storage space. Installing racks is usually preferable since it maximizes space utilization and is less expensive than adding a square foot of warehouse storage space.

Stacking: This is a type of warehouse floor storage in which one pallet is stacked on top of another. Single stacking, double stacking, and block stacking are the three types of stacking. Stacking is basic storage that does not necessitate the use of material handling equipment such as racks or shelves. Stacking is used in warehouses all around the world because of its low setup costs, versatility, and ability to maximize vertical space. Machine handling equipment (MHE) ensures safe pallet handling, and lanes are built to ensure access to various stock-keeping units (SKUs).

Pallet-less Stacking: This is the most classic stacking method that does not involve the use of pallets. Individual cartons or boxes are placed one on top of the other instead. Pallet-less stacking is still a popular storage method used in warehouses. Expensive products, such as vehicle engines, are housed on the floor without pallets, allowing for easy access to the product and total safety. Pallet-less stacking is a natural storage solution in warehouses because it requires no expenditure.

Warehouses have been a centralized and stable site for inventory storage for the past decade, and firms have decided to invest in warehouses as long-term fixed assets. Although the current market has invariable demand, it is difficult for businesses to estimate the inventory levels that must be maintained in warehouses.

While there are different types of warehouses, they are alike in terms of the inward flow of Keeping goods to storage to the outward flow. First, the received cargo is compared to the receiving cargo list, and the items, amounts, and quality are examined. The inspection may also include an acceptance examination, and if the received cargo is found to be in excellent condition, the products are placed in the warehouse. The commodities are then kept, and distribution processing and packing are completed as needed. If the volume is not substantial, warehousing and inspection data management can be done on paper in a ledger, but in warehouses and logistics management centers that receive a big amount of cargo, this is typically done with handheld computers. Based on data gathered using a handheld computer when the cargo was received and inspected, inventory management can be performed on cargo from storage until shipping.

The processes in detail are as follows

1) Receiving: Handling products into and onto a system in a warehouse.

Single things, objects, liters, cartons, packages, crates, kilograms, or complete pallets may be the subject of receipts. Pallets and split pins are also examples of huge items. An Advance Shipping Notice (ASN) from a supplier is the best approach to get supplies. Operators can scan consignment barcodes to bring up the ASN with this information on the system. The products can be system-received if the delivery matches the ASN.

2) Put Away: A letter will be sent to put-away workers informing them that stock is in staging and will be delivered to a storage facility. Operators accept the put-away task from the Enterprise Resource Program (ERP) or Warehouse Management System (WMS), then scan the necessary barcode of the goods to be put away. The system will then instruct the put-away crew to deliver the goods to the appropriate storage location. When the operator arrives at the site, he or she will scan the relevant stock location barcode or manually validate that the correct position has been discovered, then place the products in the slot before confirming that the put-away process is complete.

3) Picking: Picking can be divided into two categories.

  • Primary: This is the initial selection of things. In other circumstances, the first picking is delivered immediately to a staging area or packing bench for finalization, consignment, and dispatch, making it the last picking.
  • Secondary: This is a secondary selection process. Some primary picks are subjected to a second picking process, especially when picked products must be allocated to clustered orders (groups of orders) or discrete orders (individual orders) via a sortation process or system.


4) Sorting:  Sorting, like choosing, is an important aspect of shipping work. Sorting is the process of separating things into categories such as category or delivery destination. Manual sorting and automated sorting are the two primary categories of sorting methods. The distinction is whether the sorting is done by humans or machines. A sorter is a machine that is mostly used for automatic sorting. Sorting is divided into three categories based on how cargo is delivered to the sorting facility.

5) Dispatch: A shipping instruction form is created for the order's contents, and the worker picks the products according to the shipping instruction form (picking list). After the products are picked, distribution processing is done as needed, a shipping inspection is done to see if the products have any issues before they are packaged, and then the products are packaged and dispatched.