Slotting

How slotting works

Start by ranking SKUs by pick frequency: the number of pick lines, not units. A SKU picked 200 times a week in ones matters more to walking time than one picked five times a week by the case.

Then match the ranking to your locations. The best positions are near the start of the route, between waist and shoulder height. For example, if phone cases CASE-114 and CASE-115 are picked on most orders, they belong at the front of aisle A at waist level, while spare brackets that ship twice a month can go at the far end on the top shelf.

What to consider besides velocity

Pick frequency is the main input, but not the only one.

• Weight: heavy items go low, both for safety and so they end up at the bottom of a tote.
• Size: a bulky SKU in a prime position wastes space that could hold several fast movers.
• Affinity: items often ordered together, such as a shampoo and its conditioner, can sit side by side.
• Look-alikes: separate similar SKUs, such as sizes of the same product, to cut picking errors.
• Handling rules: temperature, hazardous goods or high-value items may need specific zones.

When to re-slot and common mistakes

Demand shifts with seasons and promotions, so slotting is never done once. Many sites review the top movers monthly and do a larger re-slot before peak season. Each move has a cost, so only move SKUs whose ranking has clearly changed.

The most common mistake is slotting by units shipped instead of pick lines. Another is re-slotting without updating location records and labels, which leaves the system and the shelf out of step. The warehouse slotting guide walks through a full review.

How NextStock supports slotting

NextStock does not generate slotting recommendations. It gives you the building blocks: location codes with a walk sequence, pick faces per SKU with min and max levels, floor moves to relocate stock, and bulk import for pick-face assignments. Operator throughput and order reports help you see which SKUs drive the most picking.