Warehouses are integral to a company’s functionality. Viewing a facility holistically boosts efficiency, profitability, and safety.
To achieve a truly integrated warehouse, follow the principles outlined below and consider working with a dedicated partner like Arnold Machinery Company.
Prioritize Flow
Prioritize the flow of goods when determining the layout instead of the current physical locations of machinery, shelves, and other necessities. Below are some common areas where flow is essential:
- Receiving: Where you retrieve products from elsewhere
- Put-Away: Where you place products upon receiving them
- Storage: Where you store long-term and short-term products
- Picking: Where you find products to ship
- Packing: Where do you package products
- Shipping: Where do you ship out products
You must identify specific areas for all tasks and choose the optimal positioning based on the product’s flow. The key is to reduce the time spent traveling to each area and the times you touch items.
Doing so improves the flow for maximum efficiency. If you notice any areas or steps in the process that slow down a vital function, eliminate them.
Integrate Smart Technology
Technology is an essential part of warehouses. To transform a facility into a single, integrated system, several possibilities exist.
Warehouse Management Systems
Warehouse management systems offer real-time visibility into processes like labor, orders, and inventory.
Gaining insight into these areas should help determine ways to streamline and turn them into a unified operation.
Data and Analytics
Data and analytics software take collected data and use it to make informed decisions. It can improve staffing, slotting, and layouts to enhance flow and unify the system.
You can store the data for future use if you open more facilities or want to implement new processes.
Automation
Automation practices reduce human error and various warehousing costs. Plenty of equipment can be automated — including advanced robotics, conveyor belts, and vertical lifts — which reduces the risk of labor shortages and boosts throughput. You should still monitor these devices to ensure they are working correctly.
You can break automation down into different categories or stages. Foundational automation includes barcode scanners and accurate tracking systems. Sorting machines and voice systems guide workers through warehouses to increase efficiency.
Some more advanced automation technologies are guided vehicles and retrieval systems.
Automation also improves staff well-being by reducing strains, lessening severe injuries, and creating upskilling opportunities. Employees can operate robots and analyze data to improve their own careers and experience.
Happier workers can streamline efficiency overall and are great to have as you implement a singular warehouse system.
Optimize Storage
Storage is another area you can adjust to create a singular warehouse. Strategically organize products to maximize storage space and the retrieval process. This saves picking time, utilizes space, improves safety, and fulfills orders quickly.
One storage strategy is to separate dynamic and static packages. Dynamic packages move quickly, so store them in an easily accessible place. Static packages may sit in storage for a while, so store them in the back or on a high shelf.
The size of each package also matters. You should place bigger items at the bottom or in the back of shelves, containers, and similar places. Consider the weight of each product, too. Heavier items go at the bottom of bins to ensure workers’ safety.
A suitable method for categorizing items is the ABC Analysis methodology. “A” items are fast-moving packages you must place in easy locations, such as selective pallet racks. “B” items are medium-range movers, so you can store them in either place depending on your own judgment and warehouse knowledge. “C” items are slow packages with a lower value, so workers can place them in drive-in or push-back racking to maximize space.
Optimizing storage is a foundational element of an integrated system because it positively impacts labor efficiency. Workers can retrieve packages quickly and easily locate specific items.
Utilize Partnerships
Designing a fully integrated system is a complex process. You would benefit from partnering with a specialist offering end-to-end warehousing solutions.
Partners assist with implementing technology, specifying equipment, and analyzing your initial warehouse layout. They can also perform site surveys, ensure components go together, and provide advanced tools.
An entity that offers end-to-end warehouse design services is Arnold Machinery Company. In business since 1944, this partner has years of reliable experience.
It provides material handling equipment and simple solutions for storage, unloading, material handling, and loading. This option also bases layout selections on your floor plan, budget, building, and projects.
Build a Safe Environment
Building a safe environment also enhances efficiency and contributes to a single, unified warehouse design. Increased safety limits accidents and brings peace of mind to staff. The following are key safety aspects to consider:
- Adequate aisle width: This ensures ample room for people and machinery to move comfortably, limiting accidents and falls.
- Designated worker and equipment zones: This keeps workers away from dangerous equipment while it is in use and alerts them when they enter an unsafe area.
- Clear signage: Signs direct teams to their designated areas throughout the warehouse, eliminating unnecessary wandering and potential accidents.
- Proper lighting: Lights illuminate areas in the warehouse to prevent mistakes and ensure everyone sees equipment, products, and each other.
Another helpful safety tip is to place frequently-used items at waist level. This can reduce muscle strain, lowering injury rates and improving morale and productivity. Ensuring safety protects warehouse workers and helps create a single, integrated system.
Test and Adjust
Once you implement a singular warehouse system, test, monitor, and adjust it accordingly. Certain processes work for some warehouses and do not for others. Identify issues and determine viable solutions, and adjust the system until everything flows smoothly.
Systems grow in complexity as new procedures and technologies enter the industry. Continuously monitoring the process helps you adapt to these new advancements and capitalize on them.
Create an Integrated Warehouse
Treat your facility as a system rather than separate parts to enhance flow. Doing so fosters long-term success and scalability. Consider working with a partner like Arnold Machinery Company to ensure you receive the best plan for your warehouse.