A manager’s job is never done. There is always a cause to undertake or situation to help control. I should know, I was a warehouse manager for a day.

Why was my tenure so short? Well, it was because my “job” consisted of directing some employees with whom I shared a unique bond….my children. We were working in General Mills Lift, Load & Haul distribution center at the Scott Family Amazeum, which provided a fantastic showcase for them to see just what efforts and machinations go into getting each and every package out to its destination.

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Online sales will account for 17% of all U.S. retail sales by 2022, up from a projected 12.7% in 2017. As you might imagine, warehouses are suffering from a major capacity crunch. Whereas previously warehouses were organized to handle large volumes of each product, E-commerce orders are characterized by a low quantity of many items or just a singular item. In an e-commerce oriented warehouse, huge quantities of SKUs exist, each needing their own specific storage slots.

Warehouse managers know that inventory levels can fluctuate anytime within a sales season, especially during a holiday when inventory levels are typically at their peak, often double or triple normal levels. Plus, because of the Amazon-effect, consumers are demanding more products with faster and better service, putting additional strain on warehouse space. Because of this growth, many businesses are looking for additional space to distribute and store products, but warehouse real estate is hard to find.

What is a retailer to do? The answer for additional space can be found within the four walls of your current operation.

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In manufacturing, maintenance, and machine shop operations, tools, dies, and bits are among the most likely targets for pilferage. Tools fit the criteria for theft we discuss in our white paper, Reducing Warehouse & Dock Area Pilferage (PDF, 1.3MB, opens in a new tab): “items that are a combination of concealable, removable, available, valuable, or enjoyable are prime candidates for theft.” Items with a high perceived “value per ounce” are at risk. A $200 block that weighs 100 pounds is far less of a target than a $200 cutting tool.

Tools are in demand, easy to sell and expensive. Plus, many of the most expensive ones fit in a coat pocket, lunch box or tool box.

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Creating a lean warehouse or DC is not something a 3PL can accomplish overnight, but it’s something that can improve your efficiency, flexibility and ability to take on new business without expanding into new facilities or massively revamping existing ones.

It takes vision, planning, strategy, tools, foresight, patience and intelligent tactics. When your warehouse is lean, it will be easier to hold, inventory, and pull the most important goods. This helps you eliminate errors, increase throughput, and satisfy customers more comprehensively.

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“The Greatest Supply Chain Show on Earth” – that was the slogan for Modex 2016 – and this year’s event at Atlanta, Georgia did not disappoint. During the busy four-day conference, we were fortunate to get a few minutes with Boyce Bonham, Director of Integrated Systems and Controls at Hytrol, a leader in the design and manufacturing of advanced conveyor systems.

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You know that your warehouse is critically important to being able to satisfy customers. You know how warehousing mistakes can impact your company’s bottom line, and how excellent warehousing can boost it. You know that a lack of resources can cripple a thriving storage or distribution operation. You also know that there are people in some organizations who don’t understand this.

Communicating the warehouse’s value is almost as important as establishing it.

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I recently attended training on a crossover and work platform product that continues to impress me for its flexibility and innovative engineering. Because of its modular design, it stands out from fabricated and manufactured products because it can morph and change as your needs change. There are times where a fixed, welded platform is fine, but it has hidden costs. Let’s examine those…

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Performance metrics are a universal way to measure a warehouse operation’s overall effectiveness, quality, and productivity. In today’s fast-paced and competitive environment, setting benchmarks and goals for a company is essential, but it’s not enough to set lofty goals for the coming year in terms of revenue, profits, or production. In the warehouse, success is the sum of all its parts. To reach overall production, quality, safety, or service goals, an examination of each step is essential. Through this evaluation process of different performance metrics, managers can find actionable information and begin prioritizing problems within a warehousing or distribution operation.

We’ve previously discussed how key performance indicators (KPIs) demonstrate the value of warehouse functions. Now, let’s take a dive deeper into five specific performance metrics to consider implementing in the modern warehouse. Read the rest of this entry »

Most people work less effectively, are less comfortable, and have poorer attitudes in a messy environment. For industrial facility operators, housekeeping can sometimes lag behind with busy days where people hardly have time to look up, much less deal with the clutter and byproducts of meeting shipping deadlines or production demands.

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In Lean Manufacturing, less is more.

A Lean operation’s ultimate goal is to eliminate waste in a system, which it achieves by creating flexibility and disposing of overproduction. Lean environments sometimes shy away from using powered conveyors in their operations, but when correctly applied, automation propels Lean Manufacturing goals—not hinders them. It’s the “secret sauce” of excellent lean manufacturing and warehousing operations.

In a true Lean environment, the customer is paramount. In other words, you need to consider what the customer wants to pay for at every point in your production. The automated solutions of today can help your Lean Manufacturing operation in three significant ways. Read the rest of this entry »