Intralogistics · Warehouse development
New Jungheinrich racking: from physical space to WMS locations
I worked on the box and tote storage project, bringing together racking, lighting, wire guidance, Wi-Fi and warehouse data. The challenge is to make the new area work as part of the existing operational flow.
Figures from the Jungheinrich dimensional specification, revision 2, January 2026. They describe the design configuration, not a final as-built survey.
01 / Adding capacity and connecting processes
In developing the new racking area, we addressed a need spanning the warehouse: providing space for boxes and totes and connecting it to storage and picking activities. Erecting the racking is only part of the work; the project also involves building services, technical teams, IT and operations.
My contribution sits at the interface between these requirements. The project plan includes technical approval, Facility and QHSE involvement, area preparation and location activation. The challenge is to coordinate activities with different dependencies so that physical availability and system availability align.
02 / The dimensions of the solution
| Quantity | Length per rack run | Depth |
|---|---|---|
| 7 | 21.70 m | 0.80 m |
| 1 | 8.70 m | 0.80 m |
| 1 | 12.00 m | 0.80 m |
| 3 | 21.70 m | 0.70 m |
The configuration specifies metal shelves, 16 storage levels and a height of 10.50 m. Main bays have a clear span of 3.50 m, with additional 1.30 m and 1.00 m bays in the shorter runs. The 12 runs total 237.70 m in length: this is a linear total, not a floor area. The number of WMS locations cannot be inferred directly from the number of shelves.
03 / The integrations behind an operational area
Lighting the new aisles
Racking changes light distribution and creates shadows in working areas. The project required lighting studies, luminaire positioning and coordination of power supply and installation. What matters is light where work takes place, not installed wattage alone. The documentation includes alternative solutions; simulation results are not presented as measurements of the completed installation.
Extending wire guidance
The new area requires continuity with vehicle guidance in the aisles. The design bill of materials specifies 335 m of single track, 30 m of double track, 72 transponders and a frequency generator. Floor preparation, including removal of remnants of previous anchors, is an upstream dependency linking civil works and material handling.
Access points and Wi-Fi
The expansion also involves terminal connectivity. Access point installation, cabling and coverage need to be coordinated with the new aisle geometry. A physically available location offers little value if an operator cannot communicate with the WMS. Final access point counts and network configurations are not included in this article.
Mapping for future storage
Rack geometry must become a usable location map: aisles, bays, levels and positions need consistent identities. This foundation supports future storage assignments and helps avoid discrepancies between the physical warehouse and the locations offered to operators by the system.
04 / From the map to location activation
The operational plan explicitly separates creating locations from opening them in the system. Preparation, labelling and testing sit between these steps, turning physical space into usable capacity.
Define and create locations
Establish aisle and location numbering and create the corresponding WMS master data aligned with the physical map.
Prepare the area
Clear the space, clean the floor and mark work areas, coordinating with racking installation and building services work.
Apply labels
Prepare and affix location, aisle, end-of-aisle and area labels, keeping system and rack codes consistent.
Check and activate
The plan calls for label testing before locations are opened. Checks need to connect the scanned code, the physical position and the expected WMS location.
05 / Next step: ABC storage classification
ABC classification is a subsequent phase still to be defined. The new map makes it possible to plan stock assignments, but it does not determine on its own which products belong in each position.
The next step will be to agree the classification criterion and observation period with Operations, using WMS data. Pick frequency, stock rotation, seasonality, dimensions and handling constraints are factors to assess together. A useful classification must also consider aisle congestion and replenishment workload.
No thresholds or percentages have yet been assigned to classes A, B and C in this account. A consistent map and reliable data come first, followed by allocation rules that can be checked and updated over time.
Space becomes capacity when the flow works
The project's value is in connecting new racking to the existing warehouse: lighting, vehicle guidance, connectivity and locations must work together. This end-to-end approach lays the foundation for storage and subsequent ABC optimisation, without confusing rack counts with measured productivity gains.
Confidentiality
Prices, costs and confidential information are not published.