GET THE MOST OUT OF YOUR WAREHOUSE STORAGE

IntroductionAugmenting a warehouse’s usable space by physical expansion is often not economically feasible due to continuous increment in real estate prices.

If the available space is not managed optimally, it leads to decreased productivity and inefficient operations.

So, what do you do to ensure that you utilize the space in your warehouse in the best way possible? 

IDEAS TO INCREASE YOUR WAREHOUSE STORAGE

Define the needs, strategic performance objectives and functional

specifications; also anticipate future expansions, reorganizations and other possibilities.

Making changes after the design and construction are completed will

be a wasteful and expensive task.

Factors to consider while designing warehouse storage layout

> SKU Analysis: Depending on the shape, size, weight, and the rate of movement of the SKUs, material storage zones should be designed.

1) Designing warehouse storage layout:

> Order Picking Accuracy: Consider material storage zones, possible order picking routes, time, labor efficiency and other factors related to order picking.

> Optimal Capacity: Run an inventory report to identify any obsolete stock that can be disposed of so that warehouse can be fill to optimal capacity.

> Storage Density: For efficient utilization of space, you need to have a high storage density of products in your warehouse.

Storage density depends on the following:

a. Aisle Width: Wide Aisle(WA): Standard wide aisles are 12’ or wider. While they provide less storage density, they enable easy movement of people, machinery and quick operations.

Narrow Aisle(NA): With widths of 8-10’, Narrow aisles pack more products in a given footprint compared to wide aisles (WA). Providing higher density than WA, these widths require specific material-handling equipment and trained workers for operations.

Very Narrow Aisle(VNA): The highest racking storage density is achieved by with aisle widths of around 5.5’. They make the most efficient usage of available space, often storing up to half of the entire stock in one footprint. However, the narrow space restricts movement, requires specialized equipment and trained personnel, making this more expensive than other Aisle systems.

b. Material Handling Equipment Selection: The cost per unit of material handled has to be worked out

for selecting the most cost-effective equipment and for the best storage density achieved.

For uninterrupted supply to customers, it is critical to maintain appropriate amounts of inventory of goods in a warehouse.

> Efficient inventory management should be employed to maintain just the right inventory levels.

> Regular inventory checks are important to identify any slow-moving or ‘dead’ inventory that is occupying precious space.

> Many software tools are available for effortless management of inventory with high accuracy.

2) Inventory Management:

Various storage solutions are available for most effective utilization of the entire vertical cube space of a warehouse.> VNA Pallet rackingAs mentioned earlier, the extremely narrow widths of these racks enable a large amount of stock to be stored with a small footprint. Pallets are stacked high to maximize on the footprint; to withstand this, pallet racks with high rigidity and compatible with VNA equipment should be used.

> Double deep pallet rackingWith racks storing pallets two rows deep, the storage capacity instantly goes up by 80%. It is ideal for high storage density with limited SKUs requirements. Double reach truck or specialized equipment is needed for storage & retrieval of pallets from the racking.

3) Appropriate Storage Systems:

> Drive-in/Driver-through pallet rackingIdeal for bulk stacking and retrieval, especially for seasonal items, these storage racks reduce selectivity but greatly increase the cube storage space and impart high storage density.

> Pushback pallet rackingIt is an accumulative system that allows multiple rows of stacking for LIFO arrangement. This storage system delivers all the benefits of a drive-in system, without having to drive in the equipment. This reduces the chances of damaged storage racks, goods and saves time.

> Mezzanine floorModular, interlocking system of easy-to-install flooring structures, Mezzanine floor is an efficient way of utilizing unused vertical space without having to invest in costly, heavy and permanent construction. The flexibility and customizability of Mezzanine floor system is a boon to those needing extra space in their existing warehouses.

> RF shuttle pallet rackingThis involves radio-controlled shuttles that move on rails to deposit as well as retrieve pallets. This is best suited for dense bulk storage and for First-In-Last-Out applications.

> Mobile pallet rackingAn ingenious system, mobile racking involves mounting warehouse storage racks or shelves on mobile “carriages” that move on rails. Operating smoothly, these mobile systems provide extra space by eliminating the number of aisles needed. Despite being movable, these “carriages” are made of high-strength components and are capable of handling heavy-duty storage items. Due to the mobile nature, all pallets are equally accessible in this system. It also creates a lot of usable space by virtue of its portability.

> AS/RS(Automated Storage & Retrieval Systems) Automated (computer-controlled) storage systems for depositing and retrieving loads from storage racks, these storage solutions maximize available space in a warehouse, reduce the cost of manual labour (as it is automated) and cut the chances of product damage or injuries. This storage system significantly improves customer service, reduce inventory and shorten order fulfillment time.

With high ceilings in warehouses, the vertical space above cross aisles can be effectively utilized by having storage racks there.

Tunnel racking can efficiently accommodate 2-3 rows of pallets in a space that would otherwise be wasted.

This will boost storage racking space by up to 10%.

4) Tunnel Racking:

The space above dock doors can be efficiently utilized, especially to store lightweight items such as empty pallets/cartons. This exploits an otherwise-neglected space in warehouse storage.

5) Rack over Docks:

6) Cross Docking: The practice of unloading pallets from manufacturers and almost immediately loading them on outbound vehicles for order fulfillment or to move to smaller warehouses, with very little time (just a few hours) spent storing them in the warehouse, is called cross docking. This saves a lot of space as well as inventory handling costs.

Evidently, several factors are in play when we talk about getting the most of your warehouse storage. Not just the interior space, but the type, weight, size and quantity of materials to be stored, the racking system, material handling equipment and the skill level of warehouse personnel, all these and customer specific requirements/challenges should be considered as vital elements to make the most optimal warehouse storage and efficient operations.

Contact us at sales@silverliningstorage.in or on +91 40 2313 9000 to effectively utilize the warehouse storage space through our insights and intelligent storage solutions.

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