Space costs money but using it to develop the optimal design that balances capacity with operational efficiency without the benefit of WMS that should include stock/demand forecasting programmes and simulation for what-ifs is asking for a sub optimal solution. The good news, however, is that such programmes can be applied retrospectively in an effort to free up space to accommodate more business as and when needed. A really good stock forecasting programme can cut stock levels by one third while leaving customer service levels unharmed, and if geared to real time weather forecasting, particularly relevant to the food and drinks industry, it can provide enough warning to meet large spikes in demand.
This article was first published in the April 1st 2020 issue of Warehouse & Logistics News, subscribe to the magazine by clicking here.
If pressed by shortage of storage space there are various measures that could avoid an expensive new build or roof-raising. There is a common perception that Britain is running out of storage space but some warehouse solution suppliers, like SEC Storage, see it more as an issue of under usage of existing space, partly because advances in MHE have made it feasible to reduce storage aisle widths by as much as 50% through use of VNA trucks and articulated forklifts. The mezzanine approach is a common solution and if less than 50% of the overall floor area may not need to be fire-rated nor need planning permission.
As the storage world, however, adjusts to the new paradigm shift towards B2C single-item picking and packing to meet online shopping, automation will play an increasing role, partly because there is a pressing need to deal with the costly, high volume of returns (reverse logistics) to get them back into storage as quickly and efficiently as possible. We are likely to see more use of live (gravity flow) storage to help with the picking process and fast sortation conveyors. The former are very compact in nature, while the latter need not take up much space because some, like the bomb-door type from B+, can be multi-tiered.
Automation, however, should not be entered into lightly. Apart from the cost there is the perception of inflexibility. This is less of a problem today because automation providers are making their kit more modular and easier to cope with future changes. But the complexity of some schemes and the various kit offerings on the market can be challenging so one route to go down is take on board a consultancy with the appropriate experience and one not tied to any equipment suppliers.
Another space constraint option is the use of a 3PL’s shared user facility. This gets around the cost of building an extension to one’s warehouse and avoids the need to commit to long-term leases. But if room on your site permits then a cheaper option could be the so-called temporary buildings. There is a wide range available, planning permission is often not a serious hold-up and installation time can be very quick, added to which there are flexible rental options.
Your chosen racking configuration will depend on the nature of one’s stored product dynamics, though with cold stores a key consideration is energy cost, stressing the need for high density. The popular choice here is mobile and drive-in racking, though the former has the edge because it allows 100% stock accessibility, albeit slowed by the necessity to open and close racking aisles.
If choosing an offsite, rented, empty warehouse to be filled with your choice of racking then it is key to avoid buying second hand racking to save money because therein lies a nest of potential safety problems.
Moreover, racking collapse defence measures should not be skimped either. The most common defence is the upright post protector but their effectiveness is limited because they only extend about 4t above ground. The only system on the market to offer complete protection against domino-style collapses, used alongside post protectors, is the patented Rhino method from RCP which secures the upright posts to a ceiling structure by steel cables.
Bill Redmond, Features Editor
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