To assist with warehouse management, materials handling and warehouse space planning, Lean Inc is providing you with helpful calculators and tools.
Problems Solved! Calculators for the Warehouse
These calculators can help you solve some of the problems you are experiencing in your warehouse.
CALCULATE SQUARE FEET
You know how many pallets you need, but you don’t know how big your warehouse needs to be. If you know this:
- Number of pallets to be stored
- Number of levels in the racking
- Aisle width
- Dock space needed
- Office space needed
This calculator will estimate the square footage (size) of the warehouse you need. CLICK: CALCULATE WAREHOUSE SQUARE FOOTAGE
INCREASE PALLET STORAGE BY DECREASING AISLE WIDTH
If you know the length x width of the storage space in your warehouse. And you know the clear height (storage height) in the warehouse, this calculator will tell you how many pallets you can store. All you do is select the type of lift truck you will use and the calculator will estimate the number of pallets you can store in the space.
Using this calculator, you can see how many more pallets you can store in any given warehouse area just by changing the lift truck type from a sit-down forklift, to reach, to deep reach and then to a turret truck.
CLICK: ESTIMATE NUMBER OF PALLETS YOU CAN STORE IN YOUR WAREHOUSE SPACE
THE COST TO MOVE RACKING IN THE WAREHOUSE
Looking to move your pallet racking around in the warehouse? Trying to figure out how much it would cost to bring a crew in to move the racking for you? This calculator compares the cost of disassembling rack the traditional way and re-erecting it to the cost of using a rack relocation system. CLICK: CALCULATE THE COST TO MOVE RACKING
ESTIMATE RACK INSTALLATION COSTS
Wondering what it would cost to install existing racking components in your warehouse? Need a professional crew to erect and anchor rack? CLICK: TO ESTIMATE RACK INSTALLATION COSTS
CALCULATE PALLETS SPACES BASED ON WAREHOUSE SPACE, AISLE DIMENSIONS AND NUMBER OF PALLETS HIGH
his calculator allows you to calculate how many pallets you can store in a given warehouse space based on a number on parameters including levels high in the racking, aisle width, number of pallets stored on the beam and number of pallets deep. CLICK: CALCULATE STORAGE CAPACITY OF A WAREHOUSE
COMPARE WHICH LIFT TRUCK AND CORRESPONDING AISLE DIMENSION STORES MORE PALLETS
Which forklift type and aisle dimension allows you to store the most pallets? Can you store more pallets in a warehouse with a 3-wheel forklift compared to a 4-wheel forklift? What percentage more pallets can you store using a reach truck compared to a forklift? How many more pallets can you store using a turret truck in the same warehouse space? CLICK: TO COMPARE THE NUMBER OF PALLETS STORED BY FORKLIFT AND AISLE TYPE
Buy Warehouse Equipment: Pallet Jacks, Racking, Shelving, Rack Repair Kits, etc Online
Full List of Helpful Free Lean Warehouse Tools and Calculators
| Calculator Name | Function | Problem it Solves | URL |
|---|---|---|---|
| Warehouse Square Footage Calculator | Estimates total warehouse square footage needed based on number of pallets, racking levels, aisle width, dock space, and office space | Helps facility managers determine how large their warehouse needs to be to store a specific number of pallets | https://store.leanmh.com/pages/warehouse-square-footage-calculator |
| Pallet Storage Capacity by Lift Truck Type | Calculates total pallet storage capacity in a given space by selecting lift truck type and available clear height | Shows how changing aisle width and lift truck type (e.g., sit-down vs. reach vs. turret) affects total pallet positions | https://store.leanmh.com/pages/pallet-storage-capacity-by-lift-truck-type |
| Rack Relocation Cost Calculator | Compares cost of moving pallet racking using a traditional disassemble-reassemble method vs. a rack relocation system | Helps warehouse teams budget for moving racking within the facility | https://store.leanmh.com/pages/rack-relocation-cost-calculator |
| Rack Installation Cost Estimator | Estimates labor cost for professional installation and anchoring of pallet racking components | Helps warehouse managers budget for installing new or used racking | https://store.leanmh.com/pages/rack-installation-cost-calculator |
| Warehouse Storage Capacity Calculator | Calculates number of pallet positions based on space available, aisle dimensions, rack height (pallet levels), and beam configuration | Helps optimize racking layout and calculate pallet capacity for a defined warehouse footprint | https://store.leanmh.com/pages/warehouse-storage-capacity-calculator |
| Forklift Aisle Comparison Calculator | Compares pallet storage capacity by forklift type and aisle width | Helps determine which lift truck and aisle dimension will store the most pallets (e.g., sit-down vs. reach vs. turret) | https://store.leanmh.com/pages/forklift-aisle-comparison-calculator |
| Design a Warehouse: New Warehouse Design Tools | Provides tools and calculators for planning new warehouse layouts, including racking, aisle widths, and storage capacity | Helps warehouse planners design efficient layouts by using multiple calculation tools in one place | https://leanmh.com/design-a-warehouse-new-warehouse-design-tools/ |
| Design Racking for Electric Pallet Stacker | Helps design pallet racking layouts optimized for electric pallet stackers | Ensures the racking layout accommodates the operating limits and aisle dimensions of electric pallet stackers | https://leanmh.com/design-racking-for-electric-pallet-stacker/ |
| Pareto’s Law Pallet Racking Calculator | Applies Pareto’s 80/20 rule to warehouse inventory and racking strategy | Helps optimize slotting and racking design based on SKU velocity and turnover patterns | https://leanmh.com/paretos-law-pallet-racking-calculator/ |
| Price for Warehouse Racking Estimator | Provides a budgetary estimate for purchasing new warehouse pallet racking | Helps warehouse managers quickly estimate the capital cost of new racking based on quantity and specifications | https://leanmh.com/price-for-warehouse-racking-estimator/ |
| Estimate Warehouse Space Needed | Estimates total warehouse space required based on the number of pallets, aisle width, and other storage variables | Helps users understand how large their warehouse needs to be for a specific number of pallet positions | https://leanmh.com/estimate-warehouse-space-needed/ |
| Install Pallet Rack | Provides guidelines, options, and factors to consider when planning for pallet rack installation | Helps warehouse managers budget and plan for professional racking installation services | https://leanmh.com/install-pallet-rack/ |
| How Many Pallets High Can I Store? | Calculates the maximum number of vertical pallet positions based on clear height and pallet + beam spacing | Helps determine how many pallet levels can safely and legally fit within warehouse clear height limits | https://leanmh.com/how-many-pallets-high-can-i-store-in-my-warehouse/ |
| Design Beam Elevations for Pallet Racking | Guides users on how to design beam elevations and spacing for pallet racking systems | Helps ensure efficient vertical space utilization while meeting safety and clearance requirements | https://leanmh.com/design-beam-elevations-beam-heights-in-pallet-racking/ |
| Optimize Warehouse Space: Warehouse Efficiency Tools | Provides links and descriptions of multiple warehouse efficiency calculators (aisle width, storage capacity, etc.) | Helps warehouse managers choose the right calculator for their space optimization challenge | https://leanmh.com/optimize-warehouse-space-warehouse-efficiency-tools/ |
| Compare Aisle Widths and Pallet Storage Capacity | Compares pallet storage density based on different aisle widths and forklift types | Helps facility managers evaluate how changing aisle widths or lift equipment can increase storage capacity | https://leanmh.com/compare-aisle-widths-and-pallet-storage-capacity/ |
| Cost Per Pallet Stored Calculator | Calculates the cost per pallet position stored based on rack cost and total storage capacity | Helps justify racking investments by breaking down the storage cost per pallet | https://leanmh.com/cost-per-pallet-stored/ |
| Pallet Rack Beam Capacity Estimator | Estimates beam capacity based on length and beam face height | Helps determine safe load capacities for pallet rack beams before purchasing or installing | https://leanmh.com/calculators/pallet-rack-beam-capacity-estimator/ |
| Increase Warehouse Capacity | Provides tips and links to multiple tools for increasing warehouse storage capacity | Helps facility managers identify strategies to maximize pallet positions within existing space | https://leanmh.com/increase-warehouse-capacity/ |
| Lumper Service | Explains warehouse lumper services for inbound and outbound freight unloading | Helps warehouse managers decide when and why to hire lumpers for pallet breakdown or build-up | https://leanmh.com/lumper-service/ |
| Move Pallet Rack | Outlines cost and planning considerations for relocating pallet racking | Helps facilities plan and budget for racking moves during warehouse reconfiguration | https://leanmh.com/move-pallet-rack/ |
| Rack Relocation System: Gondola Skate | Introduces the Gondola Skate system for moving pallet racks without disassembly | Provides a faster, lower-labor-cost alternative to traditional rack relocation | https://leanmh.com/rack-relocation-system-gondolaskate/ |
| What is the Capacity of My Pallet Racking? | Guides users in understanding and calculating the weight capacity of their pallet racking | Helps avoid overloading rack structures by calculating safe load limits | https://leanmh.com/what-is-the-capacity-of-my-pallet-racking/ |
| Forklift Maintenance Costs | Provides benchmark cost estimates for maintaining different forklift types | Helps facility managers budget and forecast forklift maintenance expenses | https://leanmh.com/forklift-maintenance-costs/ |
| Financial Justification for Updating Forklift Fleets | Provides a financial model to justify new forklift purchases by comparing maintenance, downtime, and operational costs | Helps justify forklift fleet replacements by calculating total cost of ownership and operational savings | https://leanmh.com/financial-justification-for-updating-forklift-fleets-with-new-equipment/ |
| Rail-to-Rail Dimension Calculator for Rail-Guided Orderpickers | Calculates minimum rail-to-rail distance needed for rail-guided orderpicker operation | Helps design aisle layouts for rail-guided systems to ensure safety and proper clearances | https://leanmh.com/calculate-rail-to-rail-dimensions-for-rail-guided-orderpickers/ |
| Minimum Distances Between Racking and Building Structures | Provides recommended clearances between pallet racking and building columns, walls, or obstructions | Helps warehouse designers meet safety and operational clearance standards | https://leanmh.com/optimizing-warehouse-space-minimum-distances-between-pallet-racking-systems-and-building-structures/ |
| Forklift Operation on Ramp | Explains OSHA and best practices for forklift operations on inclines and ramps | Helps prevent forklift accidents and ensures regulatory compliance when operating on slopes | https://leanmh.com/forklift-operation-on-ramp/ |
| Reach Truck Aisle Dimension Estimator | Calculates recommended aisle widths for different reach truck models | Helps determine correct aisle widths for safe and efficient reach truck operation | https://leanmh.com/reach-truck-aisle-dimension-estimator/ |
| Doosan BR20SP-7 Reach Truck Aisle Calculator | Provides aisle width recommendations specifically for the Doosan BR20SP-7 reach truck | Helps facilities plan aisle dimensions based on a specific reach truck model | https://leanmh.com/doosan-bobcat-br20sp-7-reach-truck-aisle-dimension-calculator/ |
| True Cost to Charge a Forklift Battery | Calculates electricity cost to charge a forklift battery from empty to full | Helps budget electricity costs for lead-acid or lithium forklift battery charging | https://leanmh.com/the-true-cost-to-charge-a-forklift-battery/ |
| Forklift Battery Maintenance Cost Calculator | Estimates total annual maintenance cost for lead-acid forklift batteries | Helps compare maintenance costs between lead-acid and lithium-ion batteries | https://leanmh.com/forklift-battery-maintenance-cost-calculator/ |
| Lithium-Ion vs Hydrogen Fuel Cell Calculator | Compares total operating costs between lithium-ion and hydrogen-powered forklifts | Helps companies evaluate ROI and operating costs when choosing between two alternative energy solutions | https://leanmh.com/lithium-ion-batteries-vs-hydrogen-fuel-cells-calculator/ |
| Forklift Battery Ampere-Hour Capacity Calculator | Calculates the ampere-hour (AH) capacity needed for a forklift battery based on usage hours and energy consumption | Helps select the right battery size for specific forklift application requirements | https://leanmh.com/what-is-the-ampere-hour-capacity-of-a-forklift-battery/ |
| The Price of a Forklift Battery | Provides estimated pricing for various forklift battery types (lead-acid and lithium-ion) | Helps buyers budget for battery replacement or new equipment purchases | https://leanmh.com/the-price-of-a-forklift-battery/ |
| Safe Battery Maintenance for Material Handling Equipment | Offers best practices and tips for maintaining forklift batteries safely | Helps prevent injuries and extend battery life through proper maintenance | https://leanmh.com/safe-battery-maintenance-for-material-handling-equipment/ |