Draft example — illustrative only. Not a published checklist.
Warehouse Walkthrough Checklist
Companion to Your Warehouse Shouldn’t Run on Memory. Print it or fill it on a tablet. Walk the floor after a show wave or on a quiet morning. Check what is true today — not the ideal blueprint.
Purpose: Spot where the building still runs on memory. Pick the first setup fixes worth making.
Note: Example layouts are not required floor plans. Adapt to your access and space.
Header
| Field | Notes |
|---|---|
| Date / time | |
| Who walked | |
| After which show / wave (if any) | |
| Building notes (shared door, one aisle, etc.) |
Incoming Vs Outgoing
| Check | Y / N / Partial | Notes |
|---|---|---|
| Incoming stock has a marked area | ||
| Outbound / sealed parcels have a marked area | ||
| Incoming and outgoing are not the same pile | ||
| Team can tell which is which without asking |
Locations & Labels
| Check | Y / N / Partial | Notes |
|---|---|---|
| Active pick locations have readable addresses | ||
| Address pattern is consistent (e.g. rack-row-shelf) | ||
| Labels placed the same way across bays | ||
| Top live SKUs can be found without “ask the expert” | ||
| Overstock for top SKUs has its own labeled addresses | ||
| Overstock sits near matching active stock |
Sample address in use today (if any):
Replenishment
| Check | Y / N / Partial | Notes |
|---|---|---|
| Written or spoken rule for when to replenish active from overstock | ||
| Someone owns the replenishment pass (who) | ||
| After a big show, active bins are refilled on purpose — not mid-pick scavenger hunts |
Handoffs: pick → check → pack
| Check | Y / N / Partial | Notes |
|---|---|---|
| Pick has a clear end (tote/cart/order together) | ||
| There is a check/count step before pack (person or moment) | ||
| Checked orders are kept apart from unchecked | ||
| Sealed parcels move to outbound — not back into the pick lane | ||
| Two open orders don’t share one pack surface |
Exceptions
| Check | Y / N / Partial | Notes |
|---|---|---|
| Marked exception / “needs attention” area exists | ||
| Exception orders stay apart from ready-to-pack | ||
| Named owner for resolution | ||
| Clear “resolved → back to flow” rule |
Pack Stations
| Check | Y / N / Partial | Notes |
|---|---|---|
| Clear work surface for typical box | ||
| Tape / void fill / mailers within reach | ||
| Common box sizes nearby | ||
| If 2+ stations: same supply/device layout | ||
| Lanes clear for carts (not blocked by empties/cables) |
Environment (Quick)
| Check | Y / N / Partial | Notes |
|---|---|---|
| Power where devices sit | ||
| Wi-Fi usable at benches/racks you actually use | ||
| Pack surface lit enough to read labels/counts |
First Three Fixes (From This Walk)
| Priority | Fix | Owner | Done By |
|---|---|---|---|
| 1 | |||
| 2 | |||
| 3 |
Re-walk date:
Related: If the path is “busy but broken,” follow one order — Before You Hire Another Packer, Follow One Order.