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 accommodate
pallets of various sizes to maximise flexibility and the number of pallets
stored, enhancing a warehouse's volume capacity.
Several
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. The
system 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 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. 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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