Spring is the perfect time to refresh your warehouse operations.
The dust (literally and figuratively) builds up over time, and if you’re like most businesses, a few improvement projects have been quietly sitting on the “someday” list.
Here’s your spring-cleaning checklist for a more organized, efficient warehouse:
1. Turn on ABC Analysis and Traceability
If you haven’t already, spring is the perfect time to start using ABC inventory classification and traceability in your WMS.
ABC Analysis focuses on prioritizing parts that require the most attention, based on their inventory value (unit cost) and usage (how often the part is used in production/sales).
Here’s a brief ABC breakdown:
- “A” → High-Priority Parts → High-Value → Slow-Moving
- “B” → Medium-Priority Parts → Moderate-Value → Slow-Moving
- “C” → Low-Priority Parts → Low-Value → Fast-Moving
In Visual, there are four different methods for calculating “usage”: Projected, Forecasted, Actual, and Planned.
Whichever usage method you use, the unit cost used is from the Total cost in the Costing tab of Part Maintenance. A dollar value is computed by multiplying the usage quantity by the unit cost. The parts whose value falls into the top A percent of values of all parts chosen for analysis receive an A code. The next B percent receive B codes and the next C percent C codes. You can also assign codes manually through Part Maintenance.
3. Refresh Your Labeling Strategy
Better labeling = faster picking, easier cycle counts, and fewer errors.
Evaluate if you need to get more granular — think shelf-level or even rack-level labeling. Clear, consistent labeling reduces decision-making time for warehouse staff and helps new employees get up to speed quickly.
4. Prevent “Honeycombing” or Partially Filled Bin Locations
How efficiently are you using your warehouse space?
One common pitfall occurs when a product accumulates in multiple different bin locations—stored at partial capacity.
As a result, the warehouse resembles a honeycomb with many partially filled cells.
During your spring cleaning, consider reviewing and consolidating part locations. This may be an easy way to free up warehouse capacity and decrease pick times.
5. Consider Kanban for Replenishment
If you’re constantly battling stockouts or overstock situations, a simple Kanban system might be the answer.
Kanban cards or digital signals can trigger replenishment before stock levels
get critical, helping your team stay proactive instead of reactive.
6. Part Traceability
It’s not uncommon for Visual users to shy away from turning on Trace for Parts. Trace creates a “paper” trail documenting a product’s lifecycle from raw material sourcing to production and outbound shipment. This lets everyone in the supply chain, including consumers, identify when, where, and by whom a product was made.
You might consider Trace if:
- The product has an expiry or warranty date
- Industry requirements apply
- Recalls / backtracking to RM Vendor are a possibility
- FIFO Support could benefit your workflows (i.e. picking)
Although it requires a bit more discipline—Trace can be an important tool for improving workflows and safeguarding your business.
7. Stop Pushing Off Barcoding Projects
We get it — improvement projects are easy to delay when day-to-day demands pile up.
But keeping up with smaller, more consistent process improvements will compound over time.
Start by picking one high-impact project — whether it’s reorganizing your fast movers, optimizing picking paths, or finally implementing that cycle count program — and commit to it this spring.
Final Thoughts
Warehouse organization isn’t just about neatness; it’s about making your operation faster, more accurate, practical and ready to grow.
If you’d like help identifying the biggest areas for improvement in your inventory management processes, let’s get in touch!
Written By: Paige Kunihiro
Specialized in working with warehouse teams to turn complex inventory problems into practical wins.
