Traffic consumes real capacity
Forklift routes, pedestrian paths, crossings, dock approaches and turning areas are operational requirements. Squeezing them to gain a few storage positions can reduce throughput and increase risk.
Separate people and equipment where practicable
Traffic-management approaches vary by facility, but the planning principle is consistent: understand where people and powered equipment interact and provide appropriate controls based on the actual operation and local safety requirements.
Congestion has a throughput cost
When vehicles queue or cannot pass safely, put-away and replenishment cycle times rise. A slightly less dense layout may produce more throughput if movement is smoother.
Validate the real operation
Observe peak shift changes, replenishment periods and dock activity rather than evaluating an empty warehouse. Capacity plans should reflect the busiest normal operating conditions.
Practical questions
Should I use one utilization percentage for every warehouse?
No. Inventory profile, storage system, seasonality, staging demand, handling equipment and workflow can make the same percentage perform very differently in two facilities.
Can this guide be used to approve a rack or building change?
No. It is a planning resource. Structural, fire, building, accessibility and workplace-safety requirements must be established for the actual facility by the appropriate qualified parties and authorities.