Increasing Storage Capacity with Warehouse Optimisation

The client faced significant challenges as their operations grew. Their existing warehouse setup was not equipped to handle the increasing volume of stock and the need for faster, more efficient order fulfilment. The lack of available storage space was leading to disorganisation, and they required a solution that would maximise the use of their available warehouse area. The key challenges were:

• Insufficient storage space: The warehouse couldn’t accommodate the growing inventory.

• Inefficient order fulfilment: The existing system didn’t allow for quick and easy picking.

• Underutilised vertical space: The client wasn’t taking full advantage of the warehouse’s height.

Solution

To address the client’s needs, we proposed a comprehensive solution that would not only optimise space but also streamline their picking and packing process. The key components of the solution included:

• High bay racking with anti-collapse screens: This solution utilised the full height of the warehouse, increasing storage capacity while keeping products safe and secure with anti-collapse screens.

• 2-tier mezzanine floor (1500 sq. mtr): This addition maximised the vertical space in the warehouse, offering additional storage on the second tier while allowing for safe, efficient movement of goods between levels.

• Conveyors and parcel chute: The integration of conveyors and a parcel chute ensured that goods could be moved efficiently across the warehouse, speeding up the order fulfilment process.

• Low-level picking system: We incorporated a low-level picking area to allow warehouse staff to easily pick products from ground level, reducing the need for forklifts and improving picking accuracy.

This tailored approach allowed the client to make the best use of their existing space while improving efficiency across multiple areas of their operation.

Implementation

The implementation of these warehouse optimisation solutions was completed seamlessly, with our team working closely with the client to ensure all aspects of the project were executed according to plan. The steps involved were:

• Installation of high bay racking: We installed the racking systems that took full advantage of the warehouse’s height, ensuring safe storage for all items, and added anti-collapse screens to prevent damage to goods.

• Mezzanine floor setup: A 2-tier mezzanine floor was installed across 1500 sq. mtr of space, effectively doubling the available floor space for storage without the need to expand the physical warehouse footprint.

• Conveyors and parcel chute: Our team installed the conveyor system and parcel chute to improve efficiency in the movement of goods. This allowed items to be quickly transported across different areas of the warehouse.

• Low-level picking area: The low-level picking area was designed and set up to optimise the process of order picking, ensuring that the staff could access products quickly and easily without needing to use high forklifts or complicated systems.

While our team provided the full design and setup for the storage systems, the client took charge of certain operational tasks, which demonstrated the flexibility of our service. We ensured they had all the support and guidance necessary to complete the project smoothly.

Outcome