Creating a warehouse rack layout that provides for efficient pallet storage is not the simple task that some may lead you to believe. TriFactor is a Florida licensed Professional Engineering company whose engineers have been trained to consider all aspects associated with proper warehouse layout design. As material handling industry experts, you can depend on TriFactor to look beyond simply “racking-out your warehouse,” but to also evaluate your business processes in order to reduce your operational costs. Whether you are developing a warehouse layout for a new distribution center or reconfiguring your existing facility layout to store more product, several factors need to be taken into consideration in order to facilitate the cost effective storage and retrieval of pallets as well the optimization of your warehouse space.
Here are just a few examples of factors considered when developing a warehouse design layout.
- Product Specific. What are the sizes and weights of the pallets being stored? How many pallets of each SKU need to be stored? What are the characteristics of the pallet? Can the pallet be stacked? Do any products have lot number or dating issues that require them to be handled on a first in first out (FIFO) basis? What is the velocity of each SKU? Are your SKU velocities seasonal? Do you have product launches that require heavy movement of individual SKUs over a very short period of time? Have you done a product slotting analysis?
- Method of Storage. Because SKUs move in and out of warehouses at varying velocities, a well designed storage system calls for a mixture of pallet rack storage types. Types of storage to be considered include Selective Pallet Rack, Drive-In / Drive-Through Rack, Double Deep Rack, Pushback or Pallet Flow Rack. TriFactor’s JJ Phelan, P.E wrote a White Paper on this very subject titled Selecting the Proper Rack Storage System which has been featured in many trade publications including: Food Logistics, Distribution Center Management and Plant Engineering & Maintenance Magazine.
- Operational. What operational area of the facility will the rack be used to support, for example a receiving area, staging for shipping or part of the forward order picking area? Does your inventory system require dedicated storage positions or can you have random storage?
- Building or Storage Area. What are the dimensions of the space allocated to pallet storage? What is the clear height of the building? Is the ceiling level or tapered? Are there any overhead obstructions? What is the load bearing capacity of the floor? Is the floor level?
- Lift Equipment. What types of material handling equipment, such as lift trucks, will be used in the operation? What is the capacity of the lift truck in weight and at what lift height does the capacity of the truck start to de-rate? How high can it lift? What size aisle and intersecting aisle does it require? Would you consider buying a different type of lift truck other than what you currently have if it was cost justifiable?
- Building Codes as well as Fire and Safety regulations. What are your local building codes with regard to storage of product in a warehouse? What is the minimum clearance needed from the top of the pallet load to the sprinkler heads? Is the facility located in a Seismic zone that requires special design considerations?
- Insurance. Many insurance companies will give better rates when certain storage and safety procedures are followed. In some cases, the product stored requires a specific design in order to be insured.
TriFactor offers facility design layout services for those companies in the planning stages for the construction of a new storage facility or the reconfiguration of their existing operations. Our engineers collaborate with architecture or construction firms to determine the proper pallet rack configuration when developing the overall warehouse and production layout and design. Regardless of the material handling situation, TriFactor has developed a solution process over the past 20 years which is now called the TriFactor Edge. If you’re looking for an Edge on your competition, call TriFactor today at 1-800-507-4209 to get us started solving your warehouse and distribution center needs.
For additional information on Product Slotting, Distribution Center Planning, Choosing a Conveyor System and other material handling issues go to the TriFactor Learning Center.
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