Create a free account

Warehouse sizing

Size a warehouse with numbers you can defend.

Sizing a warehouse or distribution center means putting numbers on storage positions, dock doors, labor and equipment before capital is committed. These free calculators run each calculation and state their method, and the articles below explain the reasoning behind them.

Calculators

  • Storage capacity

    Compare pallet positions, aisle counts and layouts for selective, double-deep, push-back, drive-in and shuttle AS/RS storage in your building footprint.

  • Dock doors

    Size inbound and outbound dock doors separately from pallets, trailer capacity, dwell and a design-day peak.

  • Labor and headcount

    Size labor from inbound and outbound volumes, with FTE and headcount by function, annual cost and a peak versus average comparison.

  • Conveyor and sortation

    Size sortation to peak-hour demand: sorter rate, sort lanes, induction stations and belt speed.

  • Slotting

    Velocity-slot your SKUs from a location master and pick history to cut pick travel.

  • Backlog and queue

    Compare daily inflow with capacity to see queue depth, days behind and how long a backlog takes to clear.

Read the method

Storage, racking and equipment

Dock and receiving

Layout, slotting and space planning

Throughput and capacity

Labor

Project support

Need hands on the project?

When a sizing exercise turns into a capital project, engineers from the Highbay Network take on front-end studies and RFP support, along with implementation management. Scope and rates are on the services page.

See services