It is essential to invest in storage systems such as pallet racking when setting up or upgrading a warehousing operation. Racking systems help you better and more efficiently protect and organize your inventory, which is often palletized, for efficient retrieval.
There are challenges you may encounter when it comes to installing and using a racking system. By devoting time to planning, you can prevent pitfalls and improve the efficiency of your business, meet fluctuations in demand and improve your bottom line.
Poor Warehouse Layout
It is the layout of your warehouse operation that plays a critical role in determining the best type of shelving system to meet your storage and retrieval needs. Therefore, planning the layout is critical. You need to consider obstacles, such as support columns, overhead lighting, drains and sprinkler systems, that may interfere with the ideal placement of your pallet racking system. Many warehouse managers underestimate the importance of having adequate floor space in the shipping and receiving areas, which can delay the process of storing received goods and preparing them for distribution. Workers need sufficient space to break down, mark and verify the contents of pallets prior to storage.
Low Vertical Space Utilization
Shelving systems permit you to store inventory items vertically, thereby reducing the amount of horizontal warehouse space required for storage. Clear height may be a limiting factor, but you also need to consider the reach of forklifts.
High upfront costs
The purchase or rental, assembly and installation of a racking system can be costly. In addition, the complexity of the system and its density directly affects the price of the racks. If you are starting a warehouse, you will need to budget for the project to maintain a healthy bottom line. You can reduce the upfront costs associated with racking systems by considering materials, assembly methods and rack types.
Materials and Assembly
Roll formed shelving is the least expensive option for each pallet location. It is also the most readily available and easiest to assemble. Structural racking with bolted or welded components is more expensive to purchase, more expensive to transport due to the increased weight, and more complex to assemble.
However, if you need a racking system for a warehouse that uses a lot of forklifts, the increased strength and impact resistance of structural racking can be a valuable long-term investment.
Single-depth selective racking is the least expensive and most common type used in warehouses today. The selectivity is high, but the storage density is low. If you need to increase the storage density of your warehouse, then you may need to choose no-drop/no-load racking or push-in racking. These systems cost more per pallet location due to increased manufacturing complexity.
Qualified personnel and high labor costs
You need qualified personnel to load and retrieve inventory items in order to get the most out of your racking system. Unlike shelving systems, which require no special qualifications for shelf pickers, pallet racking requires trained and certified workers to operate forklifts and other material handling vehicles, limiting the hiring pool, raising labor costs, and complicating the hiring process.
You also need to make sure your forklift drivers follow safety guidelines, have enough wiggle room between racks, and receive refresher training. In addition to the manpower needed to operate the necessary equipment, you need a fleet of forklifts that are suitable for use with the racks. Make sure the forklifts you purchase or rent have the load capacity to meet your requirements and reach the inventory at the desired height.
Automated storage and retrieval systems (AS/RS), such as vertical lift modules and horizontal turntables, reduce the need for licensed and certified workers and specialized material handling equipment. Conversely, training requirements are relatively low, reducing labor costs without sacrificing picking accuracy.
Inefficient Picking Processes
One of the most common problems in warehouse operations is an inefficient picking process or workflow. Regardless of the type of shelving or storage and retrieval system you use, inefficient selections cost time and money, especially if they increase error rates.
Using radio frequency identification (RFID) and directional picking systems can reduce the amount of time employees spend searching for materials and significantly improve picking accuracy. An example of a directional system is pick lighting, through which a series of LED lights help workers identify the box, pallet or pallet where the desired item is located.
Protective Equipment
You can reduce the risk of these hazards by installing guardrails, safety nets, lighting tape and post protectors. You should also make sure your forklift drivers are properly trained and receive regular refresher training at reasonable intervals.
Inventory Management
Another common challenge with traditional racking systems is avoiding inaccurate inventory data and other supply chain issues. Modern warehouses often use a warehouse management system (WMS) to accurately track inventory levels. It is important to track current levels in real time to ensure you have enough inventory to meet changing demand. By monitoring this metric, you can know when to order more orders, especially during seasonal peaks in demand. Using barcode technology simplifies maintaining adequate inventory levels and avoids the accumulation of unsold, expired or obsolete inventory items when using traditional shelving systems.
Improving warehouse efficiency with the right racking
At Aceally, we know that choosing the right racking system for your warehouse can present some challenges, and we’re here to help you meet those challenges. Please contact us at [email protected] and our team will be happy to guide you through our selection of racking and shelving systems to find the perfect solution for your storage needs.
Further Reading:
Several innovative approaches to using cantilevered shelving
Owns roll security container for simple and efficient warehouse storage
3 common types of mezzanine floor
Selective Pallet Racking vs Double Deep Pallet Racking
Logistics rolling security cage use guide
Post time: Jan-06-2022