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 its flexibility and the number of pallets stored, enhancing the use of 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 from 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 exacting efficiency, safety, customer satisfaction and service standards that justify the costs of warranting the investment in warehouse pallet storage and handling equipment.
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. Significant investments in automated pallet storage and handling systems and MHE training for staff will be necessary in cases involving bulk pallet movements.
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
It is crucial to ensure that the warehouse management system (WMS) requirements are met to maintain a smooth flow of products within the warehouse. Accurate labelling of 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 location 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 damages 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 used 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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