Warehouse Space Utilisation
The efficient utilisation of
space within a warehouse is a crucial aspect that needs to be addressed when
selecting warehouse storage equipment. This is particularly important when
considering pallet racking, as the choice of pallet racking determines the size
of pallets that can be stored and the mechanical handling equipment (MHE)
required to access and manoeuvre the pallets.
Suppliers often deliver
pallets in assorted sizes. Therefore, pallet racking should be configured to
accommodate pallets of various sizes to maximise flexibility and the number of
pallets stored, enhancing a warehouse's volume capacity.
Several types of pallet
racks can be configured, including narrow aisle, standard, double deep,
pushback, powered mobile, and drive-in racking. Each option has its
characteristics in terms of how it utilises the volume of warehouse space and
will need various types of MHE, including reach, counterbalance, stacker
cranes, and narrow aisle trucks.
Mechanical Handling
Equipment
The suitability of the MHE
chosen for use in the warehouse is of the utmost importance to ensure the
smooth operation of the pallet racking equipment. If the MHE is incompatible
with the pallet racking, it can decrease the efficiency of pallet movements into
and out of the racking.
Using an inappropriate type
of MHE in a pallet racking area can also violate health and safety regulations
if it poses a risk to the operator. Therefore, careful consideration must be
given to selecting the appropriate MHE to avoid compromises in efficiency or
safety breaches.
Maintaining quick and
convenient access to pallets is crucial, particularly when following an
inventory policy of first in, first out (FIFO). This becomes even more
significant when dealing with products with a limited shelf life. Effective
inventory management processes are vital in ensuring that customers receive
products within their expiration dates.
This aspect holds immense
importance in industries such as pharmaceuticals, where medical supplies may
need to be recalled, or in the food industry, where "sell by" or
"use by" dates are critical in preventing foodborne illnesses. Therefore,
it is essential to uphold efficient inventory practices to meet customer
expectations and adhere to industry legal, health and safety and customer
service standards.
Choice of Mechanical
Handling Equipment
Ensuring a warehouse
operates at optimal efficiency and maintains a high level of safety for MHE
operators requires careful consideration when selecting MHE types. Prioritising
quick and easy access to stocked items is crucial and even more critical in industries
where product expiration dates play a significant role.
The smooth flow of products
in and out of the main pallet and picking area racking is vital for the
warehouse's overall functionality. This enables the warehouse to maintain
satisfactory customer service levels and helps minimise costs.
By carefully selecting the
appropriate MHE, the warehouse can achieve seamless operations and enhance
productivity. Prioritising the ease of access to stocked items and following a
FIFO inventory policy are critical considerations in this process.
The costs associated with
the MHE system must justify the purchase and use of the equipment. Both racking
and MHE can be expensive, requiring organisations to make significant
investments to maximise the return on investment, which must be sufficient to justify
the capital expenditure.
Selecting suitable MHE
equipment increases the efficiency of product movements, maintains the
effectiveness of the pallet racking system, maximises the use of warehouse
volume capacity, and guarantees the safety of the MHE operator.
By considering these
factors, warehouses can achieve exact efficiency, safety, customer
satisfaction, and service standards that justify the costs of warranting
investment in warehouse pallet storage and equipment handling.
The Utilisation of
Mechanical Handling Equipment
Considerations regarding the
amount and utilisation of MHE depend on the expected volume of inbound
products, storage requirements, and the dispatching process. In cases involving
bulk pallet movements, significant investments in automated pallet storage and
handling systems and MHE training for staff will be necessary.
On the contrary, when
products are purchased in bulk and subsequently broken down into individual
units for dispatch to end users, known as a breakbulk operation, the need for
MHE is reduced to ensure the safe and efficient handling of products.
Manual systems are more
likely to be used for product movement within the warehouse. However, some
pallet racking and limited MHE will still be required. Even with this reduced
investment, exercising caution and minimising health and safety risks is essential.
The expected operational
outcomes should justify the decision to design and purchase MHE. In situations
with a high volume of complete pallet movements within a warehouse, the cost of
implementing fully automated MHE systems will be offset by the benefits of
increased efficiency.
Conversely, a breakbulk
operation requires less capital expenditure on MHE systems, focusing on fixed
racking and fewer equipment pieces. However, designing, configuring, and
utilising MHE types remains crucial to prioritise staff safety and well-being.
Warehouse Management System
To maintain a smooth flow of
products within the warehouse, it is crucial to ensure that the warehouse
management system (WMS) requirements are met. Accurately labelling pallet
racking locations with barcodes and uploading this information to the WMS is
essential.
Proper placement and
recording of pallets within a warehouse is vital to ensure easy retrieval when
needed. Minimising travel time facilitates the efficient movement of pallets
between different warehouse zones, such as pallet storage, picking, and dispatch
areas.
While random pallet
placement may be allowed in a bulk pallet storage area, fixed locations are
typically used in picking areas to streamline operations. Each location within
a bulk pallet storage area is designated and assigned a serial number, allowing
incoming pallets to be stored in the closest empty pallet to the fixed product
pick location.
This becomes crucial in
reducing the number of pallet movements in areas where staff are assembling
orders for dispatch from pick locations located on the ground floor of the
pallet racking area, and total pallet quantities are used to replenish pick locations.
Configuring the storage
equipment appropriately is crucial to maintaining the condition and integrity
of the stock. This ensures that the products are protected from any damage
during their movement within the warehouse.
While palletisation has
proven effective in safeguarding products from knocks and damages caused by
dropping, it is essential to consider the impact of temperature on the
integrity of stored items. If the temperature is not controlled correctly, it
can lead to product degradation.
Warehouses with different
environmental conditions, such as ambient, chilled, and freezer, are essential
to prevent potential product damage. These warehouses create an atmosphere that
limits damage by preventing bacterial growth and material decomposition. This
is particularly important for perishable items like food and medical supplies.
The storage equipment in
these conditions must be designed to withstand prolonged use in adverse
atmospheric conditions. Metals may require special treatment to prevent stress
damage in colder environments.
The products' weight should
be considered during physical handling. Heavy boxes can pose a health and
safety risk, increasing the chances of injury for staff members. Boxes that
require manual handling should be stored below head height to allow for safe
consolidation into orders before dispatch. As a rule, heavier boxes should be
stored closer to the ground.
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