This year’s Logistics Management magazine distribution center operations survey has an excellent analysis of recent warehousing trends at a national level. One of the more intriguing (and perhaps helpful) questions, was on the actions DC operators are taking to lower operating costs.

When it comes to those costs, the pressure is always on. Particularly in those unfortunate companies where the distribution center is considered just a cost, not a chance to add value. Even if you are hitting cost targets, you are probably interested in reducing operational costs without reducing effectiveness.

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I imagine most everyone has used a hand truck. They’re great for moving heavy loads faster and easier than hauling them manually. But what about unloading that hand truck once you get the load where you want it? Can your back handle the last couple of boxes at the bottom of the stack? How are your knees? How’s your upper body strength? Can everyone working in your operation safely and easily lift the load to shelving or a work table?

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Facility layout is a complex and sometimes maddening process. You are often limited by budget, space, time, or schedule beyond your control. What factors should you consider when you allocate space, either in a new facility or a redesigned one?

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It’s easy to say that you’re striving for 100% accurate pick rates, but how realistic is that goal? And should it be the actual number you shoot for? Mis-picked orders, any number of them, are expensive. Incorrect orders are expensive to re-pick. They’re expensive to return and restock. Shipping dollars are lost both directions. Most importantly, mistakes are expensive because they can cost you customers.

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