The Wisdom for Warehousing course includes Dr. Frazelle's lecture video at Georgia Tech, a fully edited and illustrated course, richly illustrated course slides, an excerpt from his World Class Warehousing book, video tours of the some of the world's best warehouse operations, and an assessment tool to compare your operations with best practices.

Warehouse storage capacity should not automatically be designed for peak demand. The optimal size depends on the peak-to-average ratio and how long the peak lasts. Short, extreme peaks can be managed with temporary storage, off-site warehousing, or delayed inbound shipments, while longer, moderate peaks justify building capacity closer to peak requirements.

RightChain’s AI-powered Slotting-as-a-Service builds on 30+ years of proven methodology to optimize warehouse operations. By continuously answering four key slotting questions—storage mode, pick face, slot location, and re-slotting—it minimizes labor, storage, and handling costs while improving productivity and accuracy. The result is a sustained 23–38% reduction in picking and restocking costs.

Honda’s warehouses were operating above 98% capacity, preventing the implementation of a new warehouse management system. By moving excess inventory to an off-site warehouse and reducing utilization to 85%, the company uncovered a large amount of unnecessary safety stock created by poor forecasting. This visibility drove major improvements to its forecasting process, inventory planning, and overall warehouse efficiency.

A retailer rejected a $2 million material-handling investment because its ROI considered only labor savings. Yet reducing dock-to-stock time from 96 to 24 hours could eliminate $6 million in inventory and significantly lower carrying costs. The case shows why supply chain investments must be evaluated holistically, capturing inventory, capital, service, and productivity benefits.

Warehousing is more than inventory storage, it enables efficient production and supply chain optimization. By supporting economical production lot sizes and seasonal inventory builds, warehouses help reduce changeover costs, improve factory utilization, and balance supply with demand. Examples of RightChain optimizations in food, beverage, and consumer goods companies show how additional storage can generate significant overall supply chain savings.

Designed using Dr. Frazelle’s World-Class Warehousing principles, the award-winning ACS Logistics Center combines AI-based slotting, packing optimization, ergonomics, automated cubing, ASRS, intelligent packing, and sorting. The design enabled ACS to consolidate its nationwide distribution network, improve warehouse efficiency, and redirect millions of dollars toward cancer research.

Zone picking can reduce travel, minimize congestion, strengthen product-location familiarity, and increase operator accountability. Examples from Xerox and True Value show how dedicated zones can improve productivity and accuracy—and even reveal slotting opportunities. However, these benefits must be weighed against added costs and control complexity through optimization and simulation before selecting the best picking design.