From a blank canvas to an operational warehouse
Getting the layout right – to meet the customers needs
In this particular case study, the customer had out-grown their premises and had bought an additional warehouse that would give them the space that they needed.
The customer needed both long term bulk storage areas and faster moving bulk storage areas to replenish stock held on the picking levels.
Customer also needed to make provision for:
Bulk long term storage
Bulk short term storage
Fast moving picking – not automated
Consolidation areas
Packing areas
Offices
Critical decisions that would effect the amount of pallet storage:
Aisle width:Very Narrow Aisle,Narrow Aisle, or Standard Aisle
Aisle width would dictate the type of trucks to buy and training packages
Loading of pallet racking would determine the length of forks on lift trucks
Floor specifications
Pallet space calculations
Pick face calculations
Pallet Racking
New or pre-used
Load Capacities
Clear entry to cope with pallet sizes
Picking stations
Creating the layout plan
The layout plan was created by WKC with our in-house cad system; having our own in-house cad system made additional thoughts and changes very quick. The customer just emailed us with any updates or operational processes that were evolving. A number of different layouts were planned and discussed in detail with the client to ensure optimal working of his warehouse.
The decision was taken to go for the narrow aisle option to maximise the storage facilities while keeping the costs down.
After all the above points were addressed and, the customer was happy, we marked out the floor plans to further check the design and then installed the racking.
Materials
Pallet Racking
This particular racking that WKC supplied was a very good quality pre-used racking with a galvanised finish. BITO system was determined as the best solution for this customer.
Picking Stations
The picking stations, which are inset under the bays, were brand new. They were durable and well priced and had ample capacity to hold the expected weights that would be placed on them.
Mesh Decks
The customer also chose to have mesh decking on all pallet levels. This was bespoke and we ordered this from abroad from a partner supplier, saving our customer money whilst gaining a superior product. Each mesh panel had 6 pallet support bars. Using this mesh, enabled even inexperienced operatives to place the pallets, (even undersized pallets), safely on the pallet racking.
Forklift
Forklift needed to operate with the narrow aisle and posting 3 pallets per level at the top level of the highest racking bay.
Our partner forklift supplier matched the customer with a Bendi truck with shorter forks (that would cope with the narrow aisle width), they also provided the training for the employees that were going to operate the truck in the environment.
We have fully trained and SIERS accredited installation crews in all areas of the UK
