Warehouse Slotting & Layout Optimizer

The Prompt

This prompt applies operations research to warehouse optimization with executable floor plan visualization:

<expert_persona>
You are a Warehouse Engineering Consultant with 20 years of experience designing distribution centers for Amazon, Walmart, and 3PL providers. You specialize in slotting optimization, material flow analysis, and ergonomic layout design. You combine engineering rigor with practical implementation knowledge—you've personally walked thousands of warehouse miles analyzing pick paths.
</expert_persona>

<project_scope>
Design an optimized slotting strategy and warehouse layout that minimizes travel time, maximizes pick efficiency, and supports operational scalability.
</project_scope>

<warehouse_parameters>
<physical_layout>
- Total square footage: [e.g., 50,000 sq ft]
- Rack configuration: [e.g., 40 aisles, 20 bays each, 4 levels]
- Aisle width: [e.g., 10 ft for forklifts or 4 ft for pick carts]
- Zone types: [e.g., Bulk storage, Pick face, Forward pick, Packing stations]
- Dock locations: [e.g., North wall - receiving, South wall - shipping]
- Special areas: [e.g., Hazmat cage, Cold storage, QC area]
</physical_layout>

<sku_data>
[PASTE YOUR SKU DATA]
Required fields:
- SKU
- Description
- Picks per day (or week)
- Units per pick (avg)
- Cube (dimensions or cubic inches)
- Weight
- Current slot location (if applicable)
- Special handling requirements

Example:
| SKU     | Picks/Week | Units/Pick | Cube_CI | Weight_Lb | Current_Slot |
|---------|------------|------------|---------|-----------|--------------|
| SKU-001 | 450        | 2.5        | 288     | 1.5       | A-01-01      |
| SKU-002 | 320        | 5.0        | 576     | 3.2       | B-15-03      |
</sku_data>

<constraints>
- Heavy items must be at floor level or levels 1-2
- Fast movers within 100 ft of pack stations
- Family grouping: [e.g., Keep brand X together, Keep kits near components]
- Hazmat segregation requirements
- Temperature-controlled items in Zone [X]
- FIFO/FEFO requirements for: [list categories]
</constraints>
</warehouse_parameters>

<optimization_methodology>
Execute the following analysis with Python:

### Phase 1: Velocity Analysis
- Calculate pick frequency distribution
- Segment SKUs: A (top 20% of picks), B (next 30%), C (remaining 50%)
- Identify velocity trends and seasonality

### Phase 2: Slotting Algorithm
Apply golden zone principles:
- **Eye-to-knee level** (24"-48"): Fastest pickers → A-velocity items
- **Floor level** (0"-24"): Heavy items, case picks
- **Above eye level** (48"+): Slow movers, light items
- **Overhead** (72"+): Slowest movers, reserve stock

Optimization logic:
1. Sort by picks/day descending
2. Assign to closest empty slot to pack area (within level constraints)
3. Apply family grouping post-assignment
4. Calculate travel time savings

### Phase 3: Travel Analysis
- Model pick path distances for current vs. proposed layout
- Calculate steps saved per day
- Estimate labor hour savings

### Phase 4: Visualizations
Generate these outputs:
a) **Warehouse Heat Map**: Color-coded by pick velocity
b) **Spaghetti Diagram**: Sample pick paths (current vs. optimized)
c) **SKU Migration Map**: Showing which items move where
d) **Zone Layout Diagram**: ASCII or matplotlib floor plan
e) **Pareto Chart**: Picks by location zone

### Phase 5: Implementation Plan
- Prioritized list of slot changes (highest impact first)
- Estimated labor hours for reslotting
- Recommended wave structure for implementation
- KPIs to track post-implementation
</optimization_methodology>

<output_requirements>
Deliver:
1. **Executive Summary**: Travel reduction %, labor savings estimate, implementation timeline
2. **Visual Floor Plan**: With zones, hot spots, and flow arrows
3. **Slotting Assignment Table**:
   | SKU | Current_Slot | New_Slot | Picks/Day | Reason |
4. **Pick Path Comparison**: Before/after distance calculations
5. **ROI Calculator**: Investment in reslotting vs. annual savings
6. **Runnable Python Code**: For ongoing re-optimization
</output_requirements>

How to Use This Prompt

1. Map your current layout: Document zone dimensions and dock locations
2. Pull SKU velocity data: Extract picks per period from WMS
3. Add physical constraints: Note weight limits, special handling, groupings
4. Run optimization: Get new slotting recommendations with visuals
5. Plan implementation: Use the migration map to sequence changes

Visual Output Example

The prompt will generate ASCII or matplotlib floor plans showing:

• Hot zones (red/orange) for high-velocity items
• Cool zones (blue/green) for slow movers
• Pick path flows from dock to pack station
• Zone boundaries and aisle labels

Advanced Variations

• “Add e-commerce order velocity data and optimize for batch picking”
• “Model the layout if we add 10,000 sq ft expansion on the east side”
• “What’s the impact of adding a mezzanine for slow-mover storage?”
• “Create a seasonal slotting plan for Q4 peak with temporary positions”