Storage and order picking equipment are crucial components in any effective, efficient warehouse system
Without effective and reliable storage and order picking systems, production and assembly lines will grind to a halt. The Just In Time (JIT) supply of parts or finished goods requires flexible and scalable warehouse storage and retrieval systems, whether manual or automated, working in combination with conveyors, Automated Guided Vehicles (AGVs) or forklift trucks.
Such systems must not only provide a smooth flow of parts through the plant, from storage to feed the line, but also accommodate future growth. And with assembly areas claiming priority over space in most factories, storage and order picking will often need to fit into a constrained footprint. Fortunately, there are many ways that these objectives can be achieved successfully.
Right first time
A good example of a lower cost and space saving method to achieve ‘right first time’ part delivery to the line comes in the form of carton or pallet live systems, comprising flow shelves created from racking. With clear labelling, flow shelves help create effective pick zones because the design provides a density of storage that results in a greater number of pick face locations than would be possible with tradition shelving and racking.
Because cartons or pallets are loaded into the flow lane on a first in, first out (FIFO) basis, when an empty unit is removed another full carton or a pallet full of parts flows into place on rollers in the inclined lane, ready to pick from.
Compared to a traditional wide aisle configuration, Very Narrow Aisle (VNA) racking provides a more space efficient solution for holding general parts, usually on pallets and is served by VNA lift trucks. This is a pretty standard solution these days, though a narrow aisle can be designed to feed a carton live structure, integrated into the rack, running alongside the aisle and providing a dense pick face for parts.
Simple small parts picking
Picking small parts is a vital element in most factory warehouses, and where the goal is to keep things simple, this can be easily integrated within pallet racks. One option is to create small parts pick locations on the reachable ground level, with upper storage levels serving as a buffer store for replenishment. Plastic small parts storage containers will help to store and organise small items and C-parts – making them available for quick and easy picking.
This will result in a reasonably efficient picking process but ground floor locations within a pallet rack will, of course, be limited. Flow shelves, however, can be easily installed into pallet racking to increase the number of pick locations and volume of SKUs located on the ground level pick face. Adding standard shelving within pallet racking is another option to create flexible small item pick faces. Using mobile shelving will maximise the available space, though moving the shelves increases pick times. Inclined shelving within a pallet racking bay will make items clearly visible for picking.
The role played by containers
Performing a vital role inside the warehouse for storage units and as order picking totes, the importance of plastic bins and containers continues outside of the warehouse where they are increasingly used for online deliveries in grocery retail logistics.
Inside a retail warehouse, plastic containers are ideal for storing a variety of SKUs on racking, shelving or in carton live storage flow lanes. Replacing existing cardboard containers that become tattered and often irregular in size on shelves with resilient plastic bins, not only adds to the protection of goods but also provides a smarter, more uniform look to the work environment.
If in live storage, an inclined tail can be placed at the end of a flow lane to tip a bin or container at an angle on the pick face to give staff better access to, and visibility of, what they are picking, thus contributing to pick accuracy. Inclining totes placed on galvanise shelving offers a similar benefit.
Goods picked from storage locations are often put into plastic order totes, which provide a convenient and protective unit to be transported around picking zones, often on a conveyor, as directed by the warehouse management system. When the picking tote is complete, having visited all the required pick zones, it can be sealed and sent to be consolidated into store orders.
Making containers work in retail logistics
Some of the bin and container designs offered by BITO to meet different retail warehouse and logistics applications include multi-purpose containers and containers manufactured from recycled material. For delivery purposes, BITO’s folding boxes and ‘stack & nest’ containers maximise storage capacity and minimise occupied space on empty return transport to cut freight costs.
Depending on the type of container there are many useful optional extras to further optimise the bin or container to its role in retail warehousing and logistics. For example, lids to protect contents from dust and dirt, which can also be security-sealed to prevent unauthorised access to goods. Dollies create convenient in-house transport. Label pockets protect labels to ensure clear barcode reading and identification. Bag holder bars, mounted on the upper sides of a container, are a particularly practical accessory for the booming online food retail business. Translucent containers with coloured attached lids offer an ideal aid for organising stock, while also helping to give visibility of products.
Having a ‘one stop shop’ supplier that can manufacturer and design racking and shelving as well as the bins and containers contained within means that both product groups are optimally adapted to each other to form a perfect bin shelving system. Selecting the right bin or container will ensure the maximum use of shelving space and spending time with BITO will enable you to find the right configuration of storage space to suit your products.
For further information, visit www.bito.com.
