Today’s warehouse managers are constantly looking for ways to run a more efficient operation. After all, ineffective operations negatively impact the business’s bottom line, customer satisfaction, workplace safety, and more. Fortunately, there are numerous storage systems warehouses can leverage to streamline their operations, such as industrial flow racks.
Flow racks are a high-density storage system that can be implemented into warehousing operations to increase space utilization and create FIFO product rotation. While they are a warehouse staple, flow racks can be deceptively complex to order and install. With a variety of styles and sizes on the market, determining the correct fit for your operation can be a challenge.
The successful implementation of flow racks requires careful planning and consideration. Mistakes in the selection, installation, and configuration of these systems can severely impede performance and operational efficiency. Here are the five most common mistakes in flow rack implementation and how to avoid them to ensure your warehouse operates at peak efficiency.
Selecting the appropriate style of track for your flow rack system is crucial for optimizing efficiency. The two primary styles of tracks used in flow rack systems are dedicated lane tracks and universal bed tracks, each with different features ideal for specific applications.
In addition to these track styles, some older styles, such as plastic wheel rails, are still in use. While plastic wheel rails can manage lightweight products with specific dimensions, utilizing this style of track comes with several limitations. Plastic wheel rails aren't as durable or efficient as dedicated lane or universal bed tracks. These older systems often lead to hang-ups and reduced flow efficiency.
Choosing the wrong style of track for your operation can lead to inefficient workflows and wasted space. For instance, using dedicated lane tracks in an environment with unpredictable box sizes can result in reduced storage effectiveness. This misalignment not only hampers productivity but also affects the bottom line by preventing optimal use of available space.
Choosing the correct track width is essential to maintaining operational efficiency and maximizing space utilization. Choosing the wrong width can lead to several issues that hinder productivity and waste valuable space.
Typically, lanes work better when they are slightly undersized compared to box width. Tracks sized in this manner are easier to pick from because workers can easily and safely slide their hands underneath and it doesn’t waste horizontal space.
To avoid the mistake of choosing the wrong track width, consider the following:
If the flow rack is too shallow, it may require more frequent replenishment, consuming valuable time and resources, reducing overall productivity, and increasing labor costs. Conversely, a flow rack that is too deep wastes vital floor space by storing more inventory than necessary for the required throughput. Overloaded racks can lead to higher carrying costs due to excess inventory and increased handling and operational costs. Additionally, if the lane depth is too great for the average inventory levels, the racks will remain partially empty most of the time, resulting in wasted capacity and inefficiency.
To avoid these pitfalls, assess your inventory turnover rate and align the lane depth with your throughput requirements. High-turnover items may benefit from shallower lanes for quick replenishment, while lower-turnover items might need deeper lanes to reduce restocking frequency. Also, consider the size and weight of the products being stored. Larger or heavier items may need deeper lanes to accommodate their dimensions, while smaller items can be stored in shallower lanes for maximum picking efficiency.
Many warehouses overlook how much space is between their SKUs — but does this even matter? Yes! Spacing SKUs is another key consideration to make when implementing a flow rack.
The optimal spacing between boxes is approximately 2”. This spacing helps maximize horizontal storage, ensuring there is enough space for workers to pick boxes up from their sides. This is important because if boxes are too close, they’re hard to pick. On the other hand, if boxes are too far apart, this wastes valuable horizontal space.
To avoid wasted space and facilitate easy inventory access, always maintain appropriate spacing between SKUs in your flow rack system.
Incorrectly sizing beams is another implementation mistake that’s easy to make. Occasionally, facilities need to repurpose existing pallet rack structures where the beams may be sized for heavier loads. However, these taller beams may take up valuable vertical space. For example, if your inventory only takes up half the vertical space on each storage level, that creates lots of wasted space that could be reconfigured.
In order to ensure warehouse space optimization, confirm the beams are properly sized for the anticipated load. This tip alone could be the difference between three, four, or even five storage levels, which could yield a 20-30% increase in storage density.
When properly planned and installed, industrial flow racks can help increase space utilization by up to 50% without expanding the existing footprint of your storage area. At UNEX, we help warehouses realize this space utilization potential with our customizable flow rack systems. Designed to maximize space, tidy messy pick areas, and improve inventory organization, let’s take a look at how these dynamic storage solutions improve warehouse operations and overall efficiency:
Warehouses can rely on FlowCell for years because it’s backed by a 7-year warranty. Plus, FlowCell is 13 times stronger than the average tube and joint modular structure, supporting up to 1,000 pounds per level because of its heavy-gauge steel construction.
Roller Rack’s modular design allows you to easily scale storage capacity up or down by adding or removing rack sections as needed. Racks can also be reconfigured with various carton flow lane styles to accommodate your changing inventory needs.
Avoiding these common implementation mistakes is important when determining the flow rack solution that’s best suited for your space. After all, every warehouse footprint and operational objective is different. That’s why creating a comprehensive plan is one of the most important steps to take before purchasing a flow rack system.
Instead of an off-the-shelf storage solution that may, or may not, fit your unique operational needs, consider a customized flow rack solution that is designed for your warehouse’s unique footprint and product offering. Not sure what type of flow rack you need to be successful and make the most out of your space?
Contact us to get in touch with a UNEX product expert. They will help you choose the right storage solutions to take your business to the next level.