Spare Parts Warehouse Sizing Calculator
Calculate the area needed for your spare parts warehouse based on the number of references, average volume and usable height available.
How is the warehouse area calculated?
Formulas: Gross volume = SKUs x Average volume, Storage area = Gross volume / Usable height, Total area = Storage area / (1 - Aisle factor).
The aisle factor represents the percentage of area dedicated to access, people circulation and material handling equipment, and typically ranges from 30% to 50% depending on the shelving and facility type.
Frequently asked questions — Warehouse Sizing
What aisle factor is typical for an industrial spare parts warehouse?
The aisle and access factor usually ranges between 30% and 50% of the total area, depending on the shelving type (static, mobile, dynamic), the material handling system used (forklifts, manual pallet jacks) and the fire safety regulations applicable to the facility.
How does usable storage height affect sizing?
The higher the usable shelving height, the smaller the floor area needed to store the same volume of spare parts. Increasing height (for example, with dynamic picking shelving or automated systems) is one of the most efficient ways to optimize available space without expanding the warehouse footprint.
Should I include a growth margin when sizing the warehouse?
Yes, it is recommended to add a 10-15% margin over the calculated area to absorb the natural growth of the spare parts catalog (new machines, new suppliers) without needing to undertake an expansion or redesign of the warehouse in the short term.
What is the relationship between warehouse sizing and the optimal stock of each spare part?
The average volume per reference used in this calculation should be based on the real optimal stock of each critical spare part (calculated based on consumption, lead time and service level). Sizing the warehouse without first knowing the optimal stock can lead to oversizing or undersizing the facility.
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