Posts Tagged ‘mezzanines’

Storage Design Theory

Thursday, December 31st, 2009

Whenever one considers storage options for their warehouse, it is very common to gravitate to merely looking at what options yield the most pallet positions.  Density, after all, is the goal.  Stick as much product as possible into a given space.

One common mistake that is made is to let density drive your design process.  Density is the ultimate goal, but focusing on operational efficiency is more critical.  Putting a system in that does match your operation may yield more pallet positions on paper, but in reality, can actually produce significantly less than anticipated.

“Pigeon Holing” as it is called can occur when the design does not match the operation.  This is where product cannot be stored in the manner in which it was designed.  This creates holes in the storage density and does not allow you to take advantage of all the positions you have created.

A common comparison is one that centers around two high density approaches, Pushback rack and Drive-In rack.

Pushback rack is where each pallet resides on a series of trays within each pallet location.  Every subsequent pallet that is placed in a particular location has the ability to “push” the previous pallet back one location.  This allows multiple pallets of the same SKU to be housed in a very dense fashion.  Pushback is an ideal LIFO (Last In First Out) storage layout.  It also allows for more pick facings giving you the ability to store a larger number of SKU’s in a given aisle.  The ideal application is one where you have multiple pallets of the same SKU that need to be stored and retrieved in a medium paced operation that does not require a FIFO (First In First Out) methodology, e.g. non-perishable items that do not have a short life-span.

Comparatively, Drive-In rack creates lanes down an aisle that allow a lift truck to travel into the lane to store product.  This is the densest storage media available.  However it has its limitations.  Only one SKU can be placed in a lane.  Once the lane is loaded, pallets must be pulled from the front backwards.  Once a pallet is removed, deeper pallet will not be available if you load the empty position back up.  So, to gain access to the back pallets, you have to leave the front positions open.  This reduces your ability to take advantage of the density you have created.  The ideal application for Drive-In rack is where you load a lane and flush that lane in its entirety.  Fast moving operations can benefit from this design.

The bottom line is: Don’t be driven by maximizing pallet positions at the cost of the efficiency of your operation.

Why use a Material Handling Systems Integrator?

Friday, February 27th, 2009

 

The definition of a material handling systems integrator would be a best described as a combination of both an allied products distributor and a consultant.  Where a consultant takes a fee based approach for their intellectual property and then assists in vendor selection, and an allied products provider is selling his brand against the competition, a true systems integrator provides the sales and implementation of material handling products as well as the intellectual property to properly engineer the solution. 

If a company has no in-house engineering the decision to use a systems integrator is fairly straight forward.  You are hiring an industry expert to advise and solve warehousing and distribution issues.  The decision becomes more difficult when the company has engineering resources.  Material handling projects are often over simplified, devaluing the role an integrator plays. 

Don’t underestimate the difficulty in implementing a truly integrated material handling system and diminish the value of an integrator.

A systems integrator:

·     Performs data analysis and system design

·     Validates the solution

·     Aids in vendor justification and selection

·     Procures the product at the best price

·     Installs the system; many times in a working environment (your operation never stops)

·     Commissions the system

 

Every day, an integrator is designing and implementing material handling projects.  The real issue is not so much about a company’s capability to handle these projects as much as it is about the risk associated with them.  Companies with engineering talent usually have an understanding of warehousing and distribution processes.  But even to the savviest of customers, integrators can add value by bringing a wide variety of experience to projects and uses that experience to mitigate risk.

Risks are often underestimated and can vary greatly depending on the type of project.  For instance, installing a system in a greenfield (new/empty warehouse) vs. an existing operation that needs to continue to operate during implementation are two dramatically different risk scenarios. 

Why use an Integrator?

·    Single point of responsibility

·    Performs various consulting functions

·    Is not a distributor.  Provides an independent evaluation of the most appropriate solution to a customer’s issues

·    Manages and coordinates multiple vendors and technologies for smooth installation

 

As projects become more complicated, the value of a systems integrator increases.

Don’t undervalue an integrators role.  Overruns on budget or schedule translate into escalating costs, both on the project and lost opportunity.