A few years ago, I looked out a Chicago hotel room window at the sub-roof of a skyscraper hotel. A long run of pipes and air ducts cut the roof in half, so that anyone who needed to work on it would have to walk a long way around or climb over. Since there were obvious points of maintenance and other equipment on both sides of the obstructions, I’m guessing that maintenance workers were doing exactly that. They needed a crossover, and a roof top isn’t the easiest place to install one, particularly post-construction.
How to Position Crossovers on Rooftops
June 9, 2020
by Scott Stone
Tags: Space Optimization
Posted in Safety & Ergonomics|
Crossing Conveyor Lines: The Options
March 19, 2019
by Scott Stone
The extensive conveyor lines that snake through many distribution facilities allow operations to transport, buffer and direct loads in a way that takes the best possible advantage of space. These conveyor systems are essentially the core around which a lean, efficient material handling operation is built, but they also create barriers to people moving around the facility since they can block the flow of foot traffic.
Tags: Shoptalk
Posted in Conveyor Optimization|
Crossovers and Work Platforms: The Advantages of Modular
March 1, 2016
by Scott Stone
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…
Tags: Space Optimization, crossover, work platform, modular, Erect A Step, Perfect A Step
Posted in Mezzanines & Industrial Platforms|
Comparison: Modular vs. Tubular Steel Crossovers
November 29, 2012
by Scott Stone
In many operations, things like conveyors or pipe runs or other machinery interrupt the flow of a work floor, and the obvious way to get around it is to erect a crossover. This is commonly done in larger scale conveyor systems with longer lines, but we also do them for other areas where going around the obstacle could take significant time, or where access is limited by other factors. The question is, what type of crossover best fits your needs?
Posted in Warehousing & Distribution|
Insights March 2026: Strategic Planning for Industrial Operations
March 3, 2026
by Scott Stone
While the landscape has never been less certain, warehousing and manufacturing professionals must still plan for 2026 and beyond. This post rounds up authorities on what to expect the next few years and how experts advise you to factor in these trends in trade, technology, artificial intelligence and more.
Read the rest of this entry »
Posted in Industry Insights|
The Golden Zone Is a Moving Target: Slotting for High-SKU Warehouses
February 19, 2026
by Scott Stone
Warehouse efficiency doesn’t fail all at once. Instead, operations slow down quietly. A few extra steps per order. A little more reaching. More waiting. Congestion forms up when you’re not thinking about it. Over time, the operation becomes heavier, less fluid, and more expensive without anyone noticing exactly when it happened.
In many cases, the cause isn’t labor, effort or faulty equipment. It’s geography.
Posted in Order Picking & Fulfillment|
Why the Best Warehouse Designs Balance Density and Access
February 5, 2026
by Scott Stone
Warehouse buildings have been getting taller: what was once a 16 to 18 foot clear-height facility is now commonly 32 to 40 feet. The logic is straightforward: taller buildings unlock more vertical storage, allowing operators to store more product without expanding the footprint. If you’re in an expensive, landlocked area and need more storage, you need to unlock every vertical inch. High bay pallet rack systems let you use all that air space and can massively increase storage density.
This is a good thing. Until it isn’t.
Posted in Pallet & Warehouse Racks|
Employee Spotlight – Marlon Richardson
January 27, 2026
In this edition of the Employee Spotlight, we talk with Marlon Richardson, Safety Manager for Cisco-Eagle. We caught up with Marlon to discuss the philosophy of the “invisible win,” his journey from the Coast Guard to the ESOP, and the intuitive rhythm of a safe warehouse.
Posted in ESOP & Company News|
OSHA’s Top Violations for 2025
December 19, 2025
Ensuring workplace safety is an ongoing challenge, especially in fast-paced manufacturing and warehousing operations. Every year, the OSHA publishes its list of the most frequently cited workplace safety violations, providing a snapshot of the most pressing hazards that can lead to injuries and serious fines.
While the list results do not have many changes from year to year, it is important to review annually. Comparing your safety processes and training to what is included can help to create a more robust system that can save lives and protect what matters.
Posted in Safety & Ergonomics|
What to Do When Your Pallet Rack Storage is Maxed Out
November 2, 2025
by Scott Stone
If you’ve worked in a warehouse long enough, you know the feeling: pallets everywhere, racks packed to the top beam, and your team playing Tetris just to make the incoming shipment fit. You’re sometimes storing pallets on the floor or holding them in the receiving area until a slot opens. It’s frustrating, destroys organization, slows everything down and ramps up safety risks. What are some things you can do to squeeze more capacity from your warehouse?
Posted in Pallet & Warehouse Racks|