Manufacturing and assembly operations face constant pressure to do more with less. Demand fluctuations, labor challenges, and the need for faster throughput all put stress on facilities that are expected to remain productive, safe, and adaptable. To stay competitive, operations must eliminate waste, streamline workflows, and adopt systems that facilitate the smooth flow of materials from one stage to the next. Among the many solutions available, flow racks have proven to be a reliable method for achieving these goals.
Flow racks are dynamic, gravity-fed systems that optimize pick and production efficiency, as well as manufacturing and warehouse storage. Flow rack systems solve the common challenges that basic, static shelving systems create. Flow racks minimize "storage sprawl" and support intuitive, ergonomic, and efficient storage, organization, and picking processes for manufacturers, retailers, and fulfillment operations.
These systems are widely used across various industries, including automotive, aerospace, electronics, and consumer goods. Wherever there is a need to store and move small parts or products efficiently, flow racks ensure items are staged properly for assembly or picking. Their versatility makes them a go-to solution for facilities that need to maintain order and flow in high-volume or high-mix operations.
The value of flow racks lies in the way they transform efficiency and ergonomics, primarily on the factory floor. By keeping materials at the point of use and always within reach, they minimize wasted motion and improve worker comfort. This not only speeds up picking and assembly but also supports safer working conditions by reducing the need for bending, lifting, and reaching.
Flow racks also facilitate FIFO (first-in, first-out) inventory rotation, an important factor in industries where product dating, sequencing, or quality control is critical. They support lean initiatives, such as JIT (just-in-time) delivery, by ensuring that the correct parts are always available in the right quantity, at the exact right place, and at the right time. By eliminating bottlenecks and reducing downtime, flow racks directly contribute to smoother workflows and higher throughput.
The modular construction of FlowCell allows for adjustments in shelf height and overall design. SpanTrack carton flow can be added to facilitate flow of materials. Angled pick shelves can help operations increase part or product visibility at the point of pick and keep items highly accessible. Accessories such as workbenches and toolbars enhance usability, while casters can be added to create mobile units that can easily be moved throughout your facility. The durability of FlowCell ensures long-term reliability while its flexibility supports continuous improvement initiatives. For facilities focused on lean, FlowCell delivers an adaptable solution that reduces waste, improves ergonomics, and increases productivity.
Because FlowCell modular flow racks can be designed and reconfigured in numerous ways, they support a wide range of functions across various operations. From enhancing ergonomics at individual workstations to improving inventory control in centralized manufacturing supermarkets, FlowCell offers teams the flexibility to design solutions tailored to their specific processes and workflows.
The following eight use cases highlight how FlowCell is commonly utilized in manufacturing and assembly environments. Each example demonstrates the versatility of modular flow racks and their measurable impact on efficiency, safety, and productivity.
FlowCell can be configured into ergonomic workstations where parts and tools are always organized and within reach. By presenting materials at the optimal height and angle, operators can maintain a steady pace without unnecessary motion. This improves assembly accuracy, reduces fatigue, and helps eliminate wasted time.
Along the production line, FlowCell serves as an ideal lineside storage solution. Components can be staged in exactly the quantities needed and replenished seamlessly. As demand shifts, racks can be reconfigured or relocated to support new layouts, ensuring that lines continue to run without interruption.
With the addition of casters, FlowCell flow racks become mobile units that can be easily moved wherever they are needed. Teams can transport parts directly to the point of use, reposition racks to support changing workflows, or quickly scale production up or down as needed. This flexibility reduces excess handling and supports JIT principles.
FlowCell racks can also be configured into robust industrial carts for moving just about anything throughout a facility. These carts streamline material handling, reduce reliance on forklifts, and minimize the risks associated with manual lifting. By bringing materials closer to operators, they improve both efficiency and safety.
Many manufacturers rely on supermarkets or small on-site warehouses to supply assembly lines with kitted parts and components. FlowCell flow racks are ideal for creating these storage systems. With clear visibility of inventory and gravity-fed replenishment, parts are always ready to be picked and restocked with minimal disruption.
In complex builds, sub-assembly is often the key to maintaining speed and quality. FlowCell provides a foundation for stations where parts can be staged, sequenced, and assembled in smaller batches before moving downstream. Configurations with single-lane units, bin levels, and presentation racks ensure that everything is organized and accessible.
For operations that need compact storage in tight spaces or small quantities of fast-moving parts, single lane FlowCell units are an efficient solution. They maximize vertical and horizontal space while ensuring that frequently used components are always available. This lean approach eliminates clutter and supports efficient replenishment.
FlowCell is often configured into presentation racks for kitting, order picking, or staging. These racks improve visibility, reduce errors, and allow workers to grab exactly what they need without hesitation. By improving speed and accuracy, presentation racks help minimize cycle times, keeping operations moving smoothly.
FlowCell modular flow racks provide the versatility manufacturers need to support lean initiatives and continuous improvement. Whether the goal is to create a customized workstation, equip a line with mobile lineside storage units or carts, or design a comprehensive supermarket system, FlowCell can be configured to meet the requirements of today's operations and reconfigured to adapt to tomorrow's challenges.
This adaptability, combined with the strength and reliability of UNEX engineering, makes FlowCell an investment that delivers long-term measurable improvements in efficiency, safety, and productivity. For manufacturers looking to eliminate waste and gain much-needed flexibility, FlowCell modular flow racks are a proven solution.