HOW TO STORE MORE IN LESS SPACE and

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1 HOW TO STORE MORE IN LESS SPACE and 25 PRODUCTIVITY TIPS FOR WAREHOUSING AND MATERIAL HANDLING

2 SPACE PRODUCTIVITY Nothing is so useless as doing efficiently that which should not be done at all Peter Drucker

3 SPACE PRODUCTIVITY Do you need to store it at all? Are you storing too much of it? Inventory management algorithms The dust test Who else can store it for you?

4 SPACE PRODUCTIVITY Where to Look Pallet Storage Shelving Storage Small Parts Storage Off site Storage Overhead what is your facility clear height? How much are you using productively? Maintenance Cribs, low activity storage Access Aisles Off site storage Multiple Facilities Trailer/mobile ministorage Drum Storage Flammable Storage Staging of Loads Dead record storage

5 SPACE PRODUCTIVITY WHERE TO LOOK Raw material storage Work in process storage Buffer storage Transit storage Finished goods storage Number of SKU s stored

6 SPACE PRODUCTIVITY We re talking more than just Storage We re talking any use of Industrial Inner Space

7 So, Let s Include Offices on Warehouse or Manufacturing Floor Special use Rooms, i.e. Lunchrooms, Training Rooms, QC Loading Dock space/layout Unused Loading Dock Bays Forklift working and cross aisles Railroad tracks inside Maintenance Areas Battery Charging/Changing HazMat Containment Floor Supported Conveyor Filing store rooms

8 SPACE PRODUCTIVITY Some Low Hanging Fruit Throw stuff away Overhead space use pre-engineered mezzanines Modular drawers instead of shelving for small parts, tools, high value inventory

9 SPACE PRODUCTIVITY Pre-Engineered Mezzanines Use space over 8 ; usually only need 15 to 17 clear to add mezzanine Free standing offers most flexibility Put offices, dead record and low access storage, lunchrooms, assembly, etc. overhead Less cost, less time than conventional construction. Faster depreciation! How to access? Permitting often required

10 SPACE PRODUCTIVITY For tools and small parts, replace shelving with modular drawers or drawers in shelving

11 OTHER SMALL PARTS STORAGE ALTERNATIVES Drawers in shelving Drawers for fast movers at counters Carousels vertical and horizontal Power Drawers (also utilize vertical space) Mini Load Systems Movable aisle storage

12 PALLET RACK PRODUCTIVITY How many pallets can you store in a given area? How do you maintain desired access to your stuff? How quickly and accurately can you pull orders?

13 PALLET RACK PRODUCTIVITY Issues affecting productivity of pallet storage Vertical spacing of pallets Horizontal spacing of pallets Aisle space and the turning space of forklifts Order picking Replenishment Accessibility parameters Speed of operations Permit and fire code issues Forklift operating characteristics Operator Training / Pay System

14 PALLET RACK PRODUCTIVITY Increase pallet rack storage capacity in a given area by Use full vertical height Rack over loading dock doors Bridge bays Store pallets by size vary vertical beam spacing Push-Back Rack in abandoned dock areas Drive In/Drive through rack

15 PALLET RACK PRODUCTIVITY Increase pallet rack storage capacity in a given area by: Changing aisles through forklift selection Counterbalanced Narrow Aisle Reach (single or double deep) Bendi Very Narrow Aisle Turret Trucks

16 PALLET RACK PRODUCTIVITY Typical Access Aisles (3,000 lb. loads) Counterbalanced forklifts 12 Double Reach Narrow Aisle 9 Single Reach Narrow Aisle 8 Turret Truck 5 ½ to 6 Bendi Turning aisles required can vary from 8 to Other forklift and rack productivity factors to consider

17 PALLET RACK PRODUCTIVITY The Manual Stack System Lower costs than automation or forklifts High value, low turn inventory Inventory control high Typical uses Maintenance parts storage Tool and die storage WIP storage Instrumentation storage High value, bulky parts storage

18 PALLET RACK PRODUCTIVITY Additional Rack Higher Density Alternatives Double deep storage rack Drive In / Drive Through rack Push Back rack Pallet Flow in rack Carton Flow in rack pick modules Rack supported multi-level pick modules

19 RACK PRODUCTIVITY Use specialized racks for odd shaped, specialized stuff Cantilever racks for long stuff Reel racks Drum racks Lubricant dispensing systems

20 PALLET RACK PRODUCTIVITY Automated Storage/Retrieval System Unit Loads Very, very narrow aisles (only crane and pallet in the aisle) Can go high real high over 40 ok, even 80 Rack supported buildings an option Other facility savings - utilities

21 SPACE PRODUCTIVITY Other Ideas Use conveyor as storage buffer eliminates rack storage Fill in old, unused dock wells Elevate offices on mezzanines Eliminate staging loads Move conveyor overhead to fee space Fill in unused railroad tracks Redo battery charging area Move HazMat storage to appropriate outside building Redo barrel storage or go to fluid handling system

22 Ask a professional to do a SPACE SURVEY of your facility Shelf Plus

23 25 PRODUCTIVITY TIPS FOR WAREHOUSING AND MATERIAL HANDLING

24 25 PRODUCTIVITY TIPS FOR WAREHOUSING AND MATERIAL HANDLING Do a histogram of forklift fleet age Reduce your forklift fleet with newer forklifts. Involve users and maintenance people in equipment selection Use conveyors for longer distance to transport cases and pallets Challenge safety folks to help increase productivity with safety Do a walk around butts in the air survey Look at door maintenance costs Look up for unused space

25 25 PRODUCTIVITY TIPS FOR WAREHOUSING AND MATERIAL HANDLING Eliminate mobile mini s and off site leasing Replace manual pallet jacks with electric Add pallet rack beams reduce vertical spacing Install mezzanine over shipping/receiving docks to utilize that space Do an inventory dust review. Throw away stuff. Evaluate palletizing and de-palletizing operations Go to hydraulic loading dock equipment Use vertical freight lifts

26 25 PRODUCTIVITY TIPS FOR WAREHOUSING AND MATERIAL HANDLING Replace carts with electric vehicles Do an energy survey of your loading dock Change to high speed doors for high traffic doors Consider a pre-built order cart system for multiple site distribution Go to modular drawers for small parts and tool storage

27 25 PRODUCTIVITY TIPS FOR WAREHOUSING AND MATERIAL Train people better HANDLING Get your people to exchange productivity ideas Use impactable overhead doors Put anti-fatigue matting wherever folks stand and work

28 Ask a professional to do a SPACE SURVEY of your facility Shelf Plus

Interpreting the Numbers: From Data to Design. William Elenbark, Consultant Gross & Associates 732-636-2666; belenbark@grossassociates.

Interpreting the Numbers: From Data to Design William Elenbark, Consultant Gross & Associates 732-636-2666; belenbark@grossassociates.com Robert Muller, Industrial Engineer Gross & Associates 732-636-2666;