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The Warehouse Map

A grid model of your actual floor. You draw aisles, storage bays and pack stations onto a canvas, link each bay cell to its real bay record, and stack levels for vertical storage. Every other feature in this document is built on top of it.

Where: Fulfillment → Warehouses → [warehouse] → Map

WHAT IT DOES

• Typed cells. A Bay cell is linked to a real storage location and displays its address. A Workstation cell marks a pack/ship point. Everything else is aisle or open floor. Colour tells you which is which at a glance.

• Multiple levels. Each level gets its own grid; add or duplicate levels and switch which one you're viewing, so mezzanines and racking tiers are modelled rather than flattened.

• Real editing tools. Click-and-drag selection, bulk type assignment, cell rotation and orientation, grid resize, view rotate/zoom — plus Range Operations to copy, mirror, move and paste whole regions of layout. Racking is repetitive; drawing it shouldn't be.

• Undo / redo / save. Layout editing is a history stack, not a series of irreversible commits. Experiment, then save when it's right.

• Structured addresses. Bay addresses are composed from a configurable format (aisle / bay / shelf / position). An axis model keeps the label your team says out loud independent of where the cell sits on the grid, so your existing naming survives the move onto a map.

• Distance is a stored property. Every bay cell carries a computed distance-to-workstation, which is what makes slotting scoring and pick routing possible.

HOW IT WORKS

Distance is walked, not measured. Distance from a bay to a workstation is a breadth-first shortest path across the grid, not a straight line — so a bay on the far side of a wall is correctly reported as far away, and a bay with no route at all is flagged as unreachable rather than silently scored.

Sparse storage. Only non-empty cells are persisted; empty floor is implied. Path finding treats any position with no stored cell as walkable, so the sparse map is walked directly with no hydration step on the server. The browser expands the full grid for display. A large plant map is a few thousand stored cells, not a few million.

Each level is capped at 250,000 cells — enough for a 500×500 floor at one cell per position — which keeps even very large sites responsive.

ONBOARDING

TRAINING

LEVERAGE

Draw once, from bays you've already New pickers get a picture of the building The map is the input to slotting scores, bulk-loaded. The map references bay instead of a list of codes. move lists, pick routing and process records rather than duplicating them. timing.

Warehouse Organizer — Feature Summaries

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F E AT U R E 0 2

Efficiency & Moves

Two buttons on the map toolbox. Evaluate Efficiency tells you how much travel and lifting exposure your current slotting is costing. Generate Moves turns that answer into an ordered, printable list of "take this product from here, put it there."

Where: Map → Operations panel · Needs: product volumes, product weights

WHAT IT DOES

• Scores your slotting. Reports the percentage of pick travel that better slotting would save, given your expected demand per product.

• Scores lifting exposure too. Reports a total safety load before and after, and the percentage reduction — so ergonomics is a number, not an opinion.

• Two dials you control. A weight-priority weight and a safe lifting limit (with unit selection) let you decide how hard the model pulls heavy items toward the pack station versus fast movers.

• Emits a move list. The optimised layout is converted into concrete product moves with source and destination addresses — work you can hand to a team on a Saturday.

• Flags unreachable bays. Bays with no walkable route to a workstation are reported and excluded rather than quietly skewing the score.

• Per-workstation analysis. Warehouses with several pack stations get an evaluation per station, ranked by opportunity.

HOW IT WORKS

The priority score. Each stored item gets a composite "pull toward the workstation" priority combining how fast it moves and how heavy it is:

priority = distanceWeight × normalisedVelocity + weightWeight × normalisedWeightOverSafeLimit

Velocity comes from the product volume you loaded (expected units per period), normalised against the fastest mover. The weight term is a hinge at your safe lifting limit : only the pounds above the limit count. A 12 lb item and a 40 lb item both score zero on safety when your limit is 50 — the model only spends its optimisation budget on loads that actually hurt people.

The re-slot. Items sorted by distance × priority ascending are matched against cells sorted by distance descending, walking high-priority stock toward the front. Travel saving is the change in total weighted distance; safety load is the sum of weight × count × distance across everything slotted.

Ordered moves, not a wish list. Move generation resolves chains: if the plan says A→B and B→C, the moves are sequenced so a destination is vacated before someone walks stock into it, and conflicting moves are deferred rather than dropped.

BEFORE YOU RE-RACK

Test the layout change on the map and read the number before touching a pallet.

SEASONAL RE-SLOT

SAFETY CASE

Reload product volumes for the new A measured reduction in heavy-load season, re-run, work the move list. travel, defensible to an EHS reviewer.

Warehouse Organizer — Feature Summaries

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F E AT U R E 0 3

Value Stream Mapping

A lean timing study built into the map. Number the steps of a process on the cells where they physically happen, then walk the floor with a stopwatch and record real cycles. The app does the statistics and tells you which step is the bottleneck.

Where: Map → Value Stream panel · Gated by: Enable Value Stream Mapping

WHAT IT DOES

• Steps live on the map. Cells carry a step number, so a process is anchored to the places it happens — receiving dock, staging, pack bench — not to an abstract flowchart.

• Segments between steps. A segment is "step 1 to step 3": a labelled measurement section with free-text observation notes.

• Stopwatch with splits. Start, split, split, split, stop. Each split records one timed sample with a timestamp. Run the same segment across many cycles and the sample set builds up.

• Lean waste tagging. Tag each segment with the wastes you observed — Defects, Overproduction, Waiting, Talent Underutilised, Transportation, Inventory, Motion, Extra Processing and Safety — so the timing data carries the diagnosis alongside it.

• Saved, named sessions. Studies persist per warehouse with a name and date. Load an old one to compare a before-and-after, or delete it.

• CSV export. Every sample, every segment average, plus the summary — exported with stable English headers so it drops straight into a spreadsheet or a report.

HOW IT WORKS

Per segment the app keeps sample count, average, minimum and maximum. Estimated cycle time is the mean of the segment averages; total process time is their sum. Both are shown, because they answer different questions — how long one typical step takes versus how long the whole run takes.

Outlier detection. Any segment whose average sits more than two standard deviations from the mean of all segment averages is flagged as an outlier step. That is the statistical version of "this one is the bottleneck" — it survives argument in a way that a gut feeling does not.

Sessions are stored per organisation and warehouse, indexed by creation date, and are covered by the same retention policy engine as the rest of your operational data.

KAIZEN EVENTS

Run a study before the change and after it, and export both.

NO EXTRA TOOLING

TIES TO LAYOUT

Replaces the clipboard, the phone A slow step on the map is often a stopwatch and the spreadsheet that slotting problem — feature 02 is one never gets typed up. click away.

Warehouse Organizer — Feature Summaries

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F E AT U R E 0 4

Rapid CSV Onboarding

Every high-volume entity accepts a bulk CSV upload with a downloadable template. The pattern is identical everywhere, so a team learns it once and loads an entire operation in an afternoon.

Where: the Create panel on each page · Pattern: download template → fill → upload

WHAT YOU CAN BULK LOAD

PAGE	WHAT THE FILE CONTAINS
Bays	Bay address, height, width, allow-partial and ignore-partial flags
Products	Product id, name, description, barcode, weight and unit, expirable flag
Inventories	Stock on hand: product, bay address, count, unit cost, expiration
Product Volumes	Expected demand per product and period — the input to efficiency scoring
Costs	Business cost records for the accounting module
Invoices / POs	Trade documents with inline line items

WHAT IT DOES

Templates, not documentation. Each upload card links its own template, so column order is never a guess.

• Validated before anything is written. Each entity has its own file-format validator that runs before persistence — a malformed file returns you to the form with the error and writes nothing.

• Errors point at the row. A non-numeric cell is reported with the bay address, the column index and the offending value — not "import failed."

Wipe and reload. Every upload card sits next to a delete-all control, because the first three onboarding attempts are always wrong.

• Or skip CSV entirely. Shopify sellers can import their catalogue — optionally including stock counts into a staging bay — straight from the channel connection.

• Recommended load order. Warehouses → bays → products → starting inventory → then draw the map on top of the bays you just loaded.

HOW IT WORKS

Streaming parse. Files are read through a streaming CSV reader off the upload's input stream rather than buffered into memory, so a large product master doesn't have to fit in the request.

Bulk insert path. Product import writes through a JDBC batch loader that bypasses the ORM for the insert itself, batching rows instead of one statement per record, with audit columns supplied explicitly so nothing is lost. It sits behind a configuration flag that restores the ordinary save path exactly when switched off.

Warehouse Organizer — Feature Summaries

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F E AT U R E 0 5

Inventory Tracking & Movement

The daily-work layer: what is stored where, how it got there, and how it moves. Each operation is its own focused screen rather than a mode buried in a general-purpose grid, so the person doing the task sees only the fields that task needs.

Where: dashboard operation tiles — Restock, Picking, Cycle Count, Replenishment, Transfer

THE SCREENS

• Bays. The storage-location registry: structured address, height and width, and partial-inventory rules ( Allow Partial , Ignore Partial Inventory ) that control whether a location can hold a broken case.

• Inventories. Product, bay address, count, unit cost and expiration date, as filterable cards or a table. Editable in place — a count correction is two clicks, not a workflow.

• Restock. Receiving: product, destination bay, physical size, count, unit cost. The same record the Inventories create panel writes, surfaced as its own flow for the people working the dock.

• Cycle Count. Say how many bays to check and the app randomly samples that many occupied bays and lists their system counts. Count them physically; any bay that's off has an Adjust button that jumps to a correction form already linked to that inventory. Accuracy checking without a shutdown.

• Replenishment. A generated queue of refill moves that keeps pick faces stocked from reserve. Tasks are raised for empty pick faces and for those that have fallen below minimum , scoped by bay-address prefix and by product, with a choice of strategy — refill the same product back into its own location, or let demand decide what belongs there.

• Inventory Moves / Transfer. An Origin panel (warehouse, bay, inventory, current availability) and a Destination panel (warehouse, bay, an existing inventory or a new one). Enter the amount and move it. Origin and destination counts change together, and the destination can be a different warehouse.

HOW IT WORKS

Bays and stock are separate records. A bay is a place; an inventory is stock sitting in that place. That separation is what lets one bay hold several products with different expiration dates, and what lets the map link to a location without owning its contents.

Moves are transactional. A transfer decrements the origin and credits the destination as one unit of work with an explicit success or failure outcome shown back to the operator — no half-moved stock.

Everything is accountable. Read and write audit trails can be switched on per organisation and queried as a report, and dataretention windows age operational data out automatically, with legal minimum floors protected for trade documents, HR records and time and attendance.

Warehouse Organizer — Feature Summaries

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