Organizing a warehouse can feel overwhelming, especially when you’re just getting started with Ply. But having a clean, efficient, and well-structured warehouse makes a huge difference in how smoothly your team operates.
In this guide, we’ll walk you through the Ply Process, a simple framework we use to help teams of all sizes set up (or reset!) their warehouses. It’s inspired by the industry-standard 5S methodology, adapted to be more practical and scalable for everyday operations. Whether you’re a team of one or managing multiple warehouses, this process is for you.
🚦When Should You Use the Ply Process?
You're preparing to implement Ply for the first time
You’ve outgrown your current warehouse setup
You’re dealing with clutter, missing parts, or inconsistent organization
You want your techs to spend less time looking for materials
🔁 The 5S Method (Industry Standard)
The original 5S system, developed by Toyota, is used worldwide to create safer, cleaner, and more efficient work environments. Here's a quick overview:
Sort – Remove items you don’t need
Set in Order – Give every item a defined home
Shine – Clean your space and keep it safe
Standardize – Build repeatable processes
Sustain – Review and maintain regularly
✅ The Ply Process: Purge, Locate, Yours
We’ve adapted the 5S approach into something simpler and more actionable, especially for smaller or growing teams. Here’s how it works:
🧹 1. Purge
Clear out unused or obsolete materials.
Toss, donate, or sell old stock
Move slow-moving items away from high-traffic areas
Reclaim shelf and floor space for what actually gets used
💡 Tip: A quick weekly sweep goes a long way.
📍 2. Locate
Give every item a dedicated spot.
Label bins, shelves, and zones
Use consistent naming or color coding
Map your warehouse layout (even a sketch helps!)
Keep fast-movers easily accessible
💡 Example: Group plumbing, electrical, and HVAC parts into separate areas.
🔁 3. Yours
Make the process your own — and stick with it.
Create checklists or task boards
Assign team members to specific areas
Walk the warehouse regularly to spot issues and improvements
💡 For small teams, even a monthly 10-minute walkthrough can help.
🧪 Example: Audit Checklist Ideas
Here are a few things you can include in a simple warehouse audit:
Aisles and walkways are clear
Tools are returned to their correct location
Barcodes and bin labels are intact
All parts are where they’re supposed to be
Notes for improvements (e.g., relabel, move heavy items lower)
🏁 How to Get Started
You don’t need to overhaul everything at once. Here’s what we recommend:
Pick a pilot area — a product category or small section
Apply Purge + Locate to that area
Create a simple checklist for ongoing maintenance
Review and adapt as needed
It’s better to start small and build up than to try and tackle everything in one go.
Still need help? Contact Support!