Madison has recently required to expand its administrative offices at its Knowlhill Distribution Centre in Milton Keynes. Thanks to a multitier mezzanine floor installation from SEC Storage they have been able to increase both office operations and storage capacity.
From 2010 to 2014
Madison is the UK’s leading distributor of bicycle parts and accessories and fastest growing freesports equipment supplier. In 2010 it opened an additional 80,000 sq/ft distribution facility in Knowlhill, converting approx. 15,000 sq/ft of pre-existing offices into a small pick zone across two floors with a Longspan shelving installation.
Early in 2014 Madison highlighted the need to increase its office operation and looked to its existing facilities for the answer. Unfortunately, they were faced with the proposition of losing significant storage capacity at the Knowlhill facility by removing Longpsan shelving from part of the facility and installing offices in its place. With significant growth projected, they could not afford to lose this vital area of their operation.
Madison therefore approached SEC Storage, the original provider of the 2010 fit out, to devise a solution to accommodate the storage capacity within the existing warehouse.
The Solution Cycle
SEC Storage firstly looked at the products and line items to be relocated. Knowing these were all single items and part of the pick pack operation, they could not be relocated into the existing very narrow aisle (VNA) pallet racking system.
The only space available within the warehouse was the existing loading bay area and VNA end of rack transfer aisle. Whilst this would provide an excellent space to relocate the Longspan shelving, it would have a significant impact on the operation and render the VNA racking almost unusable.
Following a significant feasibility study and design process, SEC Storage discovered that a multitier mezzanine could be installed in the area, without impacting on the loading bay or VNA operation.
The ground floor would be kept un-racked and instead used for the existing goods-in area. This would also leave space remaining for the transfer aisle.
The first floor would be 6000mm wide, providing sufficient storage space, yet not impacting on the transfer aisle or height required by the VNA forklifts.
The second floor would be 12,000mm wide, double the width of the first and in effect cantilever over the transfer aisle. This would provide the additional storage space required, maximising the effective footprint and height of the building, yet allowing forklifts to pass under.
Keeping the Warehouse Cogs Turning
In addition to the design, supply and installation of the mezzanine floor, SEC Storage also had the duty to turn this into an operationally efficient space.
The mezzanine structure was firstly fire rated in order to comply with relevant Building Regulations with a minimum of one hour resistance. This was achieved with a 1200mm x 600mm ceiling grid, edge protection and column cases plus a Rockwool fire barrier.
The existing Longspan shelving was relocated from the office areas and reconfigured to suit the new mezzanine floor layout over 2 floors, offering a cost saving for Madison.
In addition, carton live beds were installed to an area of the operation reserved for one of the world’s leading sports camera brands. Required to distribute in excess of 15,000 cameras, the 20 carton live beds, each consisting of 5 lanes with 2 roller tracks, were installed on the Longspan nearest the packing area. This provided easy replenishment of stock whilst operatives were not required to move to other areas of the mezzanine floor in order pick. This is the first time Madison has implemented dynamic storage and it has provided a significant uplift in pick rate and therefore operational cost savings.
The entire second floor is surrounded by an industrial mesh partition system with swipe card access to secure the operation reserved for high value cameras and electronics.
Product flow was considered for the mezzanine floor and in addition to pallet gates, SEC Storage provided a mezzanine goods lift with maximum working load of 500kgs, for the moving of goods and other bulky items. This is coupled with a spiral goods chute from 1st to ground floor for completed orders to be delivered to the despatch area.
A full electrical system was included as part of the solution encompassing lighting, illuminated exit signs, emergency break glass call points, alarm sounders and smoke detection. Other safety features included the installation of steel anti-collapse mesh whereby product was at risk of falling into pedestrian or forklift operation zones.
“SEC have worked with us on a number of projects and their ability to come up with a range of cost effective solutions to any given problem is at least as important as their track record in delivering on time and to budget,” commented Patrick Barker, Commercial Director.
Without such a solution Madison were faced with the prospect of losing vital storage space and operational integrity. The new mezzanine floor installation has enabled us to increase office facilities and at the same time increase warehouse capacity and efficiency to cope with the success and growth the company continues to experience.
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