Industrial facilities are vulnerable to an assortment of challenges related to storage and layout. Rather than allowing these challenges to persist, facilities can address the most critical issues through strategic design decisions that enhance safety, efficiency, and overall performance. Quick remedies are a well-planned layout, good organization, and specialized storage solutions.
Optimize Warehouse Layouts
Poor warehouse layout design is the cause of many problems that might not seem obvious at first glance. One of the most common is the excessive time it can take workers to get from point A to point B. Another is aisle congestion and bottlenecks, which often happen at receiving, packing, or shipping locations.
Follow-on problems include slower order fulfillment times, higher instances of product damage from excessive handling, substandard workflows between inbound and outbound merchandise, and bigger challenges when the facility is finally ready to add automation technology.
Common identifiers of poor warehouse layouts include:
- lack of clear zoning,
- lower-than-expected performance,
- shipment loading and unloading delays,
- higher-than-average worker injuries, and
- higher-than-expected picking errors.
Best practices for optimizing warehouse layouts start with prioritizing worker safety. Some of this can be achieved with high visibility zoning markers on the floor, at eye-level, and ceiling signs. Another part is making sure that pathways are well-lit and kept clear for foot traffic and machine traffic.
Consider traffic patterns as they relate to productivity. Make sure that there are direct paths for routes used most frequently. Inbound and outbound areas should be physically separated to minimize congestion. Aisles should be wide enough to accommodate human and machine traffic, in a way that offers a safe shoulder for human traffic. Finally, hard-copy maps should be posted throughout larger facilities so employees and site visitors can always readily orient themselves.
Utilize Clear Organization Systems
The benefits of having clear organization systems in place in industrial facilities cannot be overstated. Without them, reasonably minor problems can grow out of control. Until then, expect issues with employees wasting untold amounts of time searching for items; misplaced inventory, which can lead to undercounts and needless reordering; lower employee morale due to job task uncertainty and confusion; obstructed egresses; reduced accountability due to lack of storage standards; workflow interruptions; and misplaced tools, parts, and materials that require recovery.
The solutions are easily identified. First, there needs to be a standardized labeling system that’s used throughout the facility. This can be a combination of letters, numbers, and color coding for even more clarity. Avoid vague labels such as “back wall,” “in packing area,” or “low shelf near break room.” To make sure this part is absolutely clear, there should be highly visible demarcations between areas to separate them. This can be as simple as signs, fluorescent painter’s tape, or actual painted stripes. The areas should be small enough so that workers can scan the entire area with their eyes without having to pace back and forth.
Keep high-demand items readily accessible to minimize collection time. Train staff and supply them with a master key to storage locations. Lastly, make sure to routinely do audits to ensure that the system is being followed.
Implement Purpose-Built Storage Solutions
Storage isn’t a one-size-fits-all situation, especially when it’s for an industrial facility. The kind of generic shelving that’s widely available to consumers may not be able to properly support the kinds of equipment and materials that are used in these sorts of facilities. Weight alone is a huge factor.
When industrial facilities don’t have purpose-built storage solutions, the risk of injury increases. Improper stacking, overloading, and inadequate structural support can lead to material instability or shelving failure, creating hazardous conditions for personnel.
Inappropriate storage is inefficient. It’s not meant to hold certain items. A lot of wasted space exists, or items get stuffed in and overcrowded. Expensive, specialized tools get stored improperly, which can lead to damage. Inventory becomes difficult to track.
The answer is storage that’s purpose-built. There are industrial storage companies that supply storage solutions specifically made for the kinds of needs that industrial facilities have. These include solutions such as modular drawer cabinets that can be added onto as a facility scales, heavy-duty shelving and racking, mezzanines and ladders to facilitate efficient traffic paths, and mobile storage and carts to help with making sure employees have the right tool at hand and can quickly return it home.
Purpose-built storage allows for the incorporation of safe, space-efficient vertical storage solutions, so facilities save floor space. Ergonomic designs can even minimize injuries around lifting strains. There are no downsides to this kind of storage specialized for industrial facilities.
These three ideas for layout, organization, and storage will work well in any industrial facility. Best of all, they can be readily implemented, no matter the size of the facility.
Todd Timm is a project manager for HDCI Storage, a custom manufacturer and installer of heavy-duty industrial and commercial storage systems.