<![CDATA[Warehouse operational efficiency has become increasingly important for manufacturing companies because it directly affects material flow continuity, logistics costs, production responsiveness, and overall supply chain performance. However, inefficient warehouse layouts often result in excessive material handling distances, prolonged transportation time, underutilized storage space, and increased operational risks that reduce warehouse productivity. Although previous studies have demonstrated the effectiveness of facility layout optimization, material handling analysis, risk assessment, and error-proofing techniques, these approaches have largely been applied independently, limiting their ability to simultaneously improve operational efficiency and process reliability. This study proposes, implements, and validates an Integrated Warehouse Redesign Framework for enhancing warehouse operational efficiency through the integration of Systematic Layout Planning (SLP), Material Handling Analysis, Risk Assessment, and Error-Proofing within a unified improvement methodology. In the proposed framework, SLP was employed to redesign the warehouse layout based on activity relationships and space requirements, Material Handling Analysis was used to evaluate transportation performance through distance, time, and handling cost measurements, operational risk assessment was conducted using Failure Mode and Effects Analysis (FMEA) to identify and prioritize critical failure modes, and error-proofing strategies were developed using Poka-Yoke to prevent recurring operational errors. The framework was validated through an industrial case study in a manufacturing warehouse. The implementation results demonstrated significant operational improvements, including a 32.53% reduction in total material travel distance, a 28.86% reduction in material handling time, a 30.30% reduction in material handling costs, a 66.67% decrease in backtracking movements, and a 72.73% reduction in cross movements. Furthermore, warehouse space utilization increased from 71.5% to 86.9%, while overall material handling efficiency improved from 68.2% to 89.1%, indicating substantial enhancements in warehouse operational performance. The proposed framework extends conventional warehouse layout optimization by integrating facility layout planning, material handling optimization, operational risk assessment, and error-proofing into a systematic decision-making process for warehouse redesign. This study contributes to the Industrial Engineering literature by providing a comprehensive and validated methodological framework for warehouse improvement, while offering manufacturing practitioners a practical guideline for reducing operational waste, improving process reliability, and enhancing warehouse performance without requiring major facility expansion.]]>
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