"It must be somewhere in the store" is how lines lose an hour waiting for one carton of labels. A store where every location has an address can find any item in under a minute.
Give every place an address
Use a simple code: Rack - Bay - Level (add Bin if you need it).
- A-02-3 = Rack A, Bay 2, Level 3.
- Paint rack letters on the end of each rack; label every bay and level.
- Record the location in the bin card or system on every receipt and issue.
Layout principles
- Receiving, inspection, storage, HOLD and issue areas separate and marked on the floor.
- Fast-moving items near the issue counter; slow-moving items further back or higher.
- Heavy fabric rolls at the bottom, light trims higher.
- Aisles wide enough for trolleys and pallet trucks, and always clear (fire exit rule).
- Rolls and cartons on pallets or racks, about 6 inches off the floor and away from walls - protects from damp and allows cleaning and pest control.
- Keep fabric rolls horizontal on racks, not stood on end (crushes edges), and covered from dust and light.
FIFO - first in, first out
Old stock should be issued before new stock of the same item:
- Load from the back, issue from the front (flow racks do this naturally).
- Write the receive date on every carton label.
- For fabric, FIFO works within the same order and shade - never mix shades to follow FIFO.
- Check dated items (adhesives, chemicals) for expiry.
Bin card - the simplest control
| Date | Ref (GRN / Req.) | In | Out | Balance | Sign |
|---|---|---|---|---|---|
| 02 May | GRN-1045 | 5,000 | 5,000 | KA | |
| 04 May | REQ-2210 | 1,200 | 3,800 | KA | |
| 06 May | REQ-2236 | 1,500 | 2,300 | KA |
Even with ERP software, a bin card at the location helps cycle counts and shows mistakes quickly.
Tip: Start with 5S in the store: sort out dead stock, set every item in a location, shine (clean) weekly, standardise labels, and sustain with a monthly audit.
Key points
- Every location has an address; every item has a location.
- Heavy low, fast near, aisles clear, off the floor.
- FIFO within the same order and shade; bin cards keep balance visible.
