Increase Pick Faces Without Expanding? You Bet!

4 Warehouse Storage Solutions that Add Pick Slots

SKU counts rarely increase exponentially all at once. Instead, we are accustomed to adding a new SKU or adjusting to product mix changes a little at a time for our storage and fulfillment operations. At some point, however, we arrive at a day where we are simply out of inventory space. In addition, as we modify existing rack systems to accommodate new SKUs, it’s likely that we are not maximizing our potential for efficient order fulfillment. Expansion is an option, but it’s expensive, disruptive, and very long-term, so we have to ask, “Is there another way?”

The answer is yes! Here are 4 material handling solutions to consider that will add pick slots within your existing warehousing and storage space as well as increase order fulfillment efficiency and accuracy.

1. Space Optimization Evaluation

A thorough evaluation of your pick method(s), inventory, order profile, and existing space can help identify areas of poorly utilized pallet rack and pick storage as well as inefficient travel routines and even potential worker safety concerns.

2. Maximize Slotting Profiles

Explore material handling options that allow you to take advantage of vertical cube space.

• Wire decking – easily fitted onto new or existing pallet racking and used for storing
  open case items as well as split case products. Stacking cases directly on the decked rack narrows the pick face dimension from a pallet width down to a single case, thereby giving you more pick faces with a simple racking adjustment.
• Steel wire deck dividers – an optional accessory to use with your wire decking that helps keep cases orderly for loading, storing, and picking.
• Backstops – pallet rack accessory that is easily installed on the rear beam of the system to stop items from falling behind the rack with single-bay configurations.  Backstops also allow for two rows of selective rack to be placed back to back, which consolidates aisle space while doubling the number of pick faces. Backstops also increase worker safety and protect inventory from damage.

3. Get Creative with Your Pallet Racking

Utilize the lower levels and underneath your pallet rack system for high-density, case or single-item storage.

• Carton flow lanes – racking designed specifically to handle cartons and totes. Fits into standard pallet racking to create a concentrated pick area where items are loaded from the rear while gravity flow lanes keep SKUs separate as pick faces are replenished. Ergonomic design helps increase pick rates while preventing repetitive lifting injuries.
• Shelving in rack – placing shelving under and within rack structures provides perfect small parts storage and keeps the more expensive flow racking available for faster-moving SKUs.
• Double deep picking – custom-designed beams allow for the picker to enter pick racking for deeper reach back and left-to-right picking opportunities.

Pick Aisle

Rear Load Aisle for Loading

4. Industrial Mezzanines

Consider adding a multi-level pick module to make full use of your warehouse’s vertical space.

• Full-case pick – pick modules can be
• Split-case pick – pick module involving carton flow racking for each pick to tote and then onto conveyor for order fulfillment.
• Bin Modules – provide small parts storage and each pick, or individual piece storage, within the module.

Utilizing one or several of these material handling solutions may be all that you need to regain control over your expanding inventory and challenging pick rates. Contact the space optimization experts at Apex Companies and we will work with you to identify areas of your facility that are best suited for re-configuring and the most economical way to get you there.  As a one-stop shop, we can also provide full service from design through installation if you need, so just give us a call.