Classify inventory by pick frequency using ABC or similar velocity analysis to prioritise slotting effort.
Warehousing & Procurement
Slotting Optimisation Using Pick Frequency, Cube Movement and Product Affinity
Redesign warehouse slotting using pick frequency, cube movement and product affinity data to shorten travel distance and cut picking labour hours.
🗓️Duration5 training days
📚Content4 modules · 8 sessions
🎓On completionAccredited attendance certificate
About the programme
Course Overview
A warehouse laid out the way stock arrived, rather than the way it is picked, forces pickers to walk further than the work requires, and that extra travel is the single largest component of picking labour cost in most operations. This course teaches a structured approach to slotting optimisation built on three data sets: pick frequency, cube movement and product affinity. Participants learn to classify items by velocity using ABC or similar analysis, calculate cube movement to size locations correctly, and mine order history for affinity patterns that reveal which items are frequently picked together. The course covers translating this analysis into a slotting plan that places fast movers near pack-out, groups affinity items to shorten pick paths, and matches location size to unit load rather than leaving pallet positions holding single cases. Exercises use sample pick history and location data so participants practise building a slotting model, prioritising a re-slotting project within operational constraints, and measuring the travel distance and productivity gains after implementation.
Expected Learning Outcomes
Calculate cube movement per SKU to size storage locations correctly and avoid wasted or overcrowded positions.
Mine order history to identify product affinity patterns showing items frequently picked together.
Design a slotting plan that places fast movers near pack-out and shortens the average pick path.
Group affinity items within the same zone or aisle to reduce travel between frequently co-picked lines.
Sequence a re-slotting project to minimise disruption to ongoing picking and replenishment operations.
Measure travel distance, pick rate and productivity change after implementing the revised slotting plan.
Who Should Attend
Warehouse operations managers seeking to reduce picking labour cost through better slot layout.
Industrial engineers analysing pick frequency and cube data to redesign warehouse storage.
Warehouse management system administrators configuring slotting rules and location assignments.
Continuous improvement specialists running productivity projects within distribution centres.
Inventory planners coordinating slotting changes with seasonal and promotional demand shifts.
Site leaders planning a re-slotting project around an existing operational facility.
Course Modules
Select any module to see its sessions and points.
01Analysing Pick Frequency and Cube Movement
2 sessions · 8 points
Session 1Classifying Items by Pick Velocity
- Extract pick transaction history and rank SKUs by pick frequency over a representative trading period.
- Apply an ABC or similar velocity classification to separate fast, medium and slow-moving items.
- Account for seasonal and promotional spikes that would distort a single-period velocity classification.
- Cross-check velocity classification against current location assignment to quantify the scale of misalignment.
Session 2Calculating Cube Movement and Location Sizing
- Calculate cube movement per SKU by combining unit dimensions with pick frequency and order line quantity.
- Match location size and configuration, such as shelf, pallet or flow rack, to each item's cube movement.
- Identify locations holding excess empty space or overflowing into secondary storage due to poor sizing.
- Model location capacity requirements against forecast volume growth for the categories being re-slotted.
02Identifying Product Affinity Patterns
2 sessions · 8 points
Session 1Mining Order History for Affinity Relationships
- Analyse historical order lines to identify SKU pairs and groups that are frequently ordered together.
- Apply market-basket or association analysis techniques to surface non-obvious affinity relationships.
- Distinguish genuine affinity patterns from coincidental co-occurrence driven by overall high pick frequency.
- Validate affinity findings with operations staff who have practical knowledge of order composition.
Session 2Translating Affinity Into Zone Grouping
- Group affinity items within the same zone or adjacent aisles to shorten travel between related picks.
- Balance affinity-based grouping against velocity-based placement when the two criteria conflict for an item.
- Design pick zones that reflect natural order patterns rather than only supplier or category groupings.
- Test proposed groupings against a sample of historical orders to estimate travel distance reduction.
03Designing the Slotting Plan
2 sessions · 8 points
Session 1Building the Slotting Model
- Combine velocity classification, cube movement and affinity grouping into a single slotting assignment model.
- Assign fast-moving, high-affinity items to locations closest to pack-out and shipping to minimise travel.
- Set replenishment frequency and reserve storage links appropriate to each item's revised location.
- Validate the proposed slotting plan against physical constraints such as rack height and equipment reach.
Session 2Sequencing and Executing the Re-Slotting Project
- Prioritise re-slotting moves by expected productivity gain relative to labour required to execute the move.
- Sequence moves to avoid disrupting active picking during peak order windows or inventory counts.
- Update warehouse management system location records accurately as each physical move is completed.
- Communicate layout changes to picking staff with updated maps and location labelling before go-live.
04Measuring Results and Sustaining the Layout
2 sessions · 8 points
Session 1Measuring Travel and Productivity Impact
- Measure average travel distance per order before and after re-slotting using warehouse management system data.
- Track pick rate and lines per hour by zone to confirm productivity gains from the revised layout.
- Attribute productivity change to slotting specifically by controlling for other concurrent process changes.
- Report re-slotting results to operations leadership with labour hours saved and payback on project cost.
Session 2Maintaining Slotting Accuracy Over Time
- Set a review cycle to re-run velocity and affinity analysis as product mix and demand patterns shift.
- Build triggers that flag SKUs whose pick frequency has changed enough to warrant a location review.
- Incorporate new product introductions and discontinuations into the ongoing slotting maintenance process.
- Assign clear ownership for slotting governance so layout discipline does not erode after the initial project.
What the participant receives
4 course modules
A structured syllabus
8 training sessions
across 5 days
32 detailed points
Applied, detailed content
Accredited attendance certificate
On completing the programme
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