(Courtesy: Consolidated Construction at flickr.com)
In the first installment of Finding More Space When Expansion Isn’t an Option, I discussed what causes space issues in the first place. Here I will cover what you can do to alleviate the problem.
Three things can alleviate space limitations in a warehouse. They include:
1. Creating storage areas outside the warehouse
2. Redesign the warehouse interior
3. Improve inventory management
Outside or Temporary Storage
Outside the doors of your warehouse is land that can be used to host temporary storage facilities. Bahrns.com offers a variety of sheds and other temporary buildings that could prove ideal for the creation of temporary storage areas outside. In addition, warehouses have been known to actually store products on trailers for short periods of time. This option could prove costly. It is said that using a trailer could cost between $180 to $220, not including drop-off charges, trailer loading and unloading labor costs, and security risk. Storage in trailers might work well if the warehouse has a partnership with a carrier. Often carriers will manage freight and store trailers in their yard as part of a freight agreement. A carrier might be inclined to make such a deal because he may be able to get a deal that includes guaranteed freight throughout the year and being able to charge a profitable rate for all routes.
Another method to make it through temporary space problems is to make an agreement with another warehouse to store extra inventory or ship orders to customers. One way to make this work is to build an alliance with another company that has different seasonal peaks, but the same storage needs. The two companies can make an agreement with a third party for storage base on a year-round contract.
Warehouse Redesign
Ways to use warehouse redesign include:
· Using available space more efficiently.
· Creating a more efficient method of material handling.
· Using economical storage.
· Building flexibility into your warehouse storage design to accommodate seasonal storage and handling issues.
Experts have identified eight steps that could be used to make the four points happen. They are:
1. Measure the space you work with.
2. Defined fixed barriers in warehouse construction including columns, walls, doors, clearance, and more.
3. Knowing the products you’re storing and handling. For example, you can define storage zones, create throughput/replenishment requirements, have a plan for unit handling loads.
4. Create material flow paths
5. Determine auxiliary facility requirements for offices, dock staging, hold and inspection and more.
6. Generate alternatives.
7. Evaluate alternatives
8. Recommend and execute improvements.
Be Creative in Developing More Space
Unique use of space can include:
· Better use of space above loads.
· Utilizing building clearance.
· Using space above cross aisles.
· Using space above work and pick areas.
· Using space above docks.
Tunnel racks can be used in areas above cross aisles. Moreover, since dock activity occurs in the lower 10-feet of the facility, then using areas above this such as above dock doors or the use of racks on the walls rather than on the floor. In addition, you can construct mezzanines above work areas or use mezzanines as work areas.
Alternative Storage Methods
Different storage options can be used including:
· Narrow Aisle Pallet Racks
· Very Narrow Aisle Pallet Racks
· Increasing Pallet Operation to 66-inches rack-to-rack.
· Double-Deep Pallet Racks and Pushback Racks
· Pallet Flow Racks
· Small Parts Storage
Finally, you can improve inventory management by receiving inventory information in real-time. This can be achieved with a real-time warehouse management system to track inventory and transaction data.