Scott Stone | Warehousing Insights | Material Handling Systems - Part 10
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The Process of Specifying Pallet Flow Rollers & Wheels

August 3, 2021
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Various types of pallet flow rollers being compared for application and load suitability.

Above – left to right: reinforced resin wheels. split rollers, full-width rollers, steel skatewheels. Each roller type has advantages in terms of versatility and capacity, depending on your load and environment.

Pallet flow rack is one of the most space-efficient, first-in, first-out high-density pallet storage and picking systems available. Because the first pallet stored in a flow lane is always the first pallet picked at the front, you constantly rotate inventory. It’s a simple concept but the execution can be complex based on the load size, weight and other characteristics. One of the most important decisions is the type and style of roller needed.

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Posted in Pallet & Warehouse Racks|

Ways to Pick Full Cases Faster, More Accurately and More Ergonomically

July 16, 2021
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full case picking from carton flow rack

Case picking is common in most e-commerce, retail and wholesale distribution operations, so it’s important to understand the best ways to pick cartons from start to finish through a process. Most warehouse operations will need at least some case-picking capacity. Beverage and grocery distributors almost always need a large full case picking function. Since order picking commands a high percentage of distribution center labor costs, finding ways to make it more efficient is critical.

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Posted in Order Picking & Fulfillment|

Bowing, Leaning and Out-of-Square Pallet Racks: Causes & Solutions

July 8, 2021
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A row of heavily loaded pallet rack in an industrial warehouse.

Racks will often be damaged over a long lifetime of use. When you see a bent beam, out-of-square beam, damaged upright or other issues with your pallet racks, you can’t ignore it.

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Posted in Pallet & Warehouse Racks|

Choosing the Right Pallet Conveyor

June 15, 2021
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heavy pallet load of cans moving on a powered conveyor line

Above: a powered roller conveyor transporting a heavy load at Simmons Pet Foods.

Pallet conveyors transport skids, pallets, sheets and other extremely heavy loads. This can be accomplished with chains, belts, rollers or even ball transfers. The pallet conveying solution is critical for efficient, speedy product or process flow. Given the options, which conveyor type is right for you?

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Posted in Conveyor Optimization|

How to Safely Modify Your Pallet Racks

June 1, 2021
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Pallet rack design and reconfiguration is a process you must engage carefully.

The nature of pallet racks—adjustable beams and teardrop connections on uprights—invites reconfiguration. Many rack manufacturers’ beams easily connect to other manufacturers’ teardrop uprights, which lets you mix & match components. This versatility can invite trouble if all the factors aren’t considered. Before you adjust beams, add new loads or reconfigure your racks, consider all the factors.

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Posted in Pallet & Warehouse Racks|

How to Help Drivers Park Faster & Safer at Your Truck Docks

May 18, 2021
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Dock lasers work in darkness, helping drivers find the right lane at a busy receiving dock.

Warehouse managers tend to focus on internal processes, equipment and systems, but making your dock apron and loading zone more efficient will save time, money and damage. Truck drivers who can’t clearly see the right dock in darkness or poor weather can’t maneuver effectively or square up to the dock quickly. They often must back in and out multiple times. Helping drivers align and organize will improve the entire flow of your shipping and receiving operation.

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Posted in Docks & Shipping|

Pallet Rack Clearances: Lateral, Vertical and Building Structures

May 11, 2021
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Warehouse rack with worker placing a pallet into tight space on a pallet rack

One of the critical aspects of pallet rack system design, aside from the specs of the rack itself, are the various clearances between rack components, the loads and the surrounding environment. Flue space can be critical for fire safety compliance. Space between a rack row and the row behind it can contribute to a safer and more effective rack system. Narrow aisles can contribute to accidents. Too tall? You could cause damaged and falling inventory, as well as damage to fixtures or HVAC components.

At the end of the day, the space around the rack is nearly as important as the rack itself.

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Posted in Pallet & Warehouse Racks|

How to Design and Utilize Storage Buffers

April 20, 2021
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Bulk storage buffer at a warehouse

Buffers can be found in most warehouses and manufacturing facilities, and they take many forms. You can build buffers into racks, floor space, conveyors or external storage areas like truck trailers. When you need to temporarily store materials before they enter putaway, shipment, kitting, processing, or another production process, what are some of the best design, equipment specification and usage practices?

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Posted in Space Optimization & Planning|

Improve Productivity with Ergonomic Storage System Design

April 15, 2021
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Carton flow storage loaded with the most frequent picks in the golden zone for ergonomic efficiency.
For order pickers, packers and others in industrial facilities, warehouse ergonomics is critical to both safety and effectiveness. The way you store and pick can enhance productivity — or hamper it. In an age of labor shortages and spiraling costs, it pays to design for ergonomics. The core of that is where you place items for picking and processing.

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Posted in Safety & Ergonomics|

How to Make Packing More Efficient

April 6, 2021
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Automated packing area for an ecommerce distribution center, pick-to-totes operation.

Above: in this automated e-commerce distribution center, picks are packed into cartons from totes on the conveyor line. Because conveyors deliver the totes directly to workers, and the work is executed at ergonomic heights, the process is fast and efficient.

Order fulfillment is only as fast as its slowest function, and packing–often the last stop before shipping–can be a bottleneck. We’ve analyzed many operations that underestimated the needs of the packing department from the start, while others realized over time that new requirements, new SKUs and order volumes that were fine at go-live eventually bogged the packing function. It’s not unusual for picking processes to react faster and better to these conditions than the packing area.

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Posted in Order Picking & Fulfillment|

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