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.
🎥 Want to Learn More?
Watch this short training session by Ryan Marsh (Ply’s Warehouse Implementation Manager), where he explains the Ply Process and how to implement it in real-world warehouses of all sizes: