Let’s face it. It is not easy managing a warehouse. All sorts of problems from systemic to outside factors can adversely affect the smooth operation of a warehouse. Systemic problems can include poorly planning slot allocation, bottleneck issues, and over packing. Outside influences can include globalization and eCommerce. Whatever the problem and from wherever it is coming from can keep warehouse managers jumping.
Some of the more common problems that seem to be puzzling warehouse managers these days include poor housekeeping, not measuring, poor slot allocation, excessive checking, over packing, globalization, and the influence of eCommerce.
Now that we have identified the issues, how do you go about fixing them?
Poor Housekeeping
Bad record taking, crowded storage areas, blocked aisle ways, forklifts running in all sorts of places, blocked doorways. The housekeeping list goes on and on. A simple way of handling the problem is to avoid it. Develop and implement a plan for storage allocation and forklift operation and encourage employers to adopt work practices that keep the aisles and doorways clear.
Measure What Needs to be measured
Running a warehouse involves measuring all sorts of things from the width of the aisles to the time it takes for a picking team to collect orders. It is imperative to keep a good record of intake, output, carryover, average time in the warehouse, labor cost of operation per item, productivity, etc., etc. Don’t just measure one day out of a month or a week. Measure each and every day so you know that the operation is running efficiently. A quick identification of a problem and addition of a quick solution to that problem can ensure that productivity remains constant.
Plan Slot Allocation
Slotting the right available space to particular products is essential to achieving optimum picking times. Make certain that the most popular products are slotted in the most accessible location and those slots are not too small or too big. Slotting should be evaluated often.
Taking Advantage of Item Arrivals
Warehouses receive things; they don’t just send things out. Some products you get in arrived pre-packed and ready for postage. Set up your operation so you can take advantage of the incoming so all you have to do is slap the postage label on the box and send it out.
Disproportionate Checking
Some times because of the nature of the beast, a warehouse crew may confront bottlenecks before packing due to excessive checking periods. A barcode and weight checking systems will assist in creating an almost ideal checking procedure without the logjam.
Over Packing
Packing is a procedure that can be a major source of bottlenecks. There are times when your crew may be too enthusiastic about their job and contribute to the slow down. Offer training to them that prevents overenthusiasm from slowing the process down too much.
Demanding Customers
Customers who are getting use to one-day or same-day delivery require warehouses to create very specific labels. You will need a warehouse system that automatically accommodates these customers’ demands –- you will need an automatic labeling system that will create the proper customized labels every day.
Globalization
In today’s market, no matter where you are, your competition is working hard in Mexico, China, and Eastern Europe. To compete, you will need to keep overhead low.
eCommerce
Because of the Internet the marketplace you serve is worldwide. You need to be and have the capability to take orders on the Internet.