By definition, manufacturing is a world of moving parts. Each order — large or small — must flow through the assembly line smoothly, and every component must be accessible and accounted for to create maximum picking efficiency.
In this fast-paced, finely tuned environment, every small organizational adjustment matters. The tiniest tweaks in layout or product accessibility can generate massive ripple effects. By implementing lean manufacturing storage solutions, manufacturing warehouses can boost productivity and profitability. UNEX FlowCell flow racks are specially designed for manufacturing facilities that want to reduce maintenance and operational costs.
Common Industry Storage and Maintenance Challenges
Like many industries, manufacturers have faced unprecedented challenges in recent years. Supply chain upheaval, economic unpredictability, inflation, and labor market disruptions leading to staff shortages are just a few of the pressures weighing on manufacturing facilities.
These external problems have been compounded by a variety of issues in the production environment:
- Storage inefficiencies: When parts are poorly organized on the assembly floor, it creates more unnecessary product movement and results in more wear and tear on products, shelving, and equipment. Parts and tools may get lost frequently, and the production and maintenance process slows down. All of this results in higher maintenance and operational costs.
- Difficulty maintaining traditional storage systems: Traditional storage structures may not be optimized for the manufacturing environment or may be built with cheap materials, such as plastic wheel rails that break easily. This, too, can result in costly slowdowns and increased maintenance expenses.
- Space constraints: Lack of available space has been a consistent trend in manufacturing facilities in recent years. These constraints lead to inefficient layouts and workflows for assembly and production.
How FlowCell Flow Racks Reduce Costs
Without a significant overhaul of the production environment, these troubles will be present regardless of what external challenges face the industry. Dynamic storage solutions like modular flow racks can play a critical role in streamlining warehouse operations by adding lineside storage, mobile carts, or presentation racks to make products more visible and accessible on the assembly line.
For instance, FlowCell flow racks offer a modular storage solution that’s easy to implement and maintain. These durable shelves are 13 times stronger than tube-and-joint structures, and they can be assembled in less than an hour. Once in place, they’re easy to maintain and adjust as needed.
Not only that, but FlowCell also dramatically improves organization in your warehouse, enhancing space utilization by up to 50%. Its flexible, reconfigurable storage shelves allow you to shift and reorganize parts to optimize workflows and accommodate process changes, reducing wear and tear on components.
How FlowCell Flow Racks Maximize Space and Reduce Operational Costs
Modular manufacturing storage solutions like FlowCell offer warehouses a straightforward solution to many of the pressures they face. Whether it’s a lack of space or labor constraints, implementing dynamic storage solutions can unlock new levels of efficiency and productivity.
Here’s how FlowCell can help you make the most of your space while reducing the cost of maintenance and other operational expenses.
1. Utilize Space Effectively
FlowCell flow racks help unlock more of your warehouse for optimal space utilization. Instead of spreading parts and inventory horizontally across the production floor, you can take advantage of vertical space with shelves tailored to your unique specifications. With shelves that are angled toward the picker, even parts stored up high are accessible.
Additionally, FlowCell’s modular design allows you to use these racks in a wide range of situations. Whether you need lineside storage, a mobile cart, or a simple assembly station, you can use your space as efficiently as possible.
2. Improve Inventory Management
First-in, first-out (FIFO) inventory management is fundamental to any assembly line, helping avoid overstocking and understocking and reducing the costs of maintaining inventory. With easy access from the back and the front, angled shelves enable simplified FIFO management, ensuring that parts and components are stocked and readily available when needed.
More broadly, FlowCell flow racks are designed to support lean manufacturing storage principles by facilitating just-in-time production and continuous inventory flow. This approach reduces waste across the board, allowing workers to focus on their specific tasks and ensuring that essential parts and components are always at hand. By streamlining the storage and retrieval process, FlowCell racks can boost production efficiency by 30%, significantly reducing downtime and operational costs.
FlowCell racks also help maintain a well-organized workspace, which is vital in manufacturing environments where the timely and accurate assembly of parts and components is critical. The improved accessibility and organization provided by these racks minimize the time workers spend searching for items, in turn increasing overall productivity.
3. Enhance Ergonomics
Worker strain and injuries are common in manufacturing facilities, particularly where layout and shelving haven’t been optimized for accessibility. Where workers have to reach behind products or high upon shelves, accidents and injuries are inevitable.
Dynamic storage solutions like FlowCell eliminate many of these problems by making more parts and accessories available right at the pick face. This does more than just reduce expensive health care and workers’ comp cases — it also limits potential product and shelf damage, further reducing maintenance costs.
Learn lean manufacturing storage principles. Download the Lean Manufacturing Storage Guidebook!
Elevate Your Storage With UNEX FlowCell Flow Racks
As a dynamic storage solution, all flow racks stand apart from traditional static shelving by letting gravity do the work. Simple, angled shelves deliver products straight to the pick face and help minimize unnecessary inventory sprawl.
But, what makes UNEX FlowCell flow racks unique?
Unlike many other storage solutions, FlowCell racks are specially designed to meet the needs of modern manufacturing facilities. They offer several benefits to help you elevate your manufacturing storage and production process:
- Modular design allows for maximum flexibility for lineside storage, fixed workstations, mobile storage, roller racks, pick trays, and more.
- Units are made for portability and reconfigurable to fit your production needs at any given time.
- Steel gauge construction enhances durability, reducing the need to replace bent or broken tube-and-joint modular structures.
- Quick and easy assembly allows you to get set up in less than an hour.
- Ergonomic design keeps parts in view and within reach, minimizing the risk of worker strain.
- Mix and match parts to build your own, and spend less time measuring, cutting, or reordering incorrect tube lengths.
Altogether, FlowCell flow racks will substantially reduce your maintenance bill and optimize your operation for greater productivity. Warehouses that implement FlowCell boast an average ROI of six months or less.
Unlocking Efficiency & Reduce Costs With FlowCell
Dynamic, modular storage solutions are an essential component of any manufacturing facility. With today’s supply chain delays, labor constraints, and tight turnaround times, warehouses must be primed to move quickly as orders come through or inventory changes.
Flow racks — and FlowCell, in particular — facilitate fast-paced fulfillment in a fast-moving production environment. These durable, flexible storage solutions boost productivity and reduce maintenance costs across the board, no matter the unique needs of your facility.
Connect with us today, and we’ll help you envision how FlowCell can enhance your warehouse production operations.
