New Year Resolution – Smart Strategies for a Smart Warehouse

New Year Resolution – Smart Strategies for a Smart Warehouse

Picture this – it’s a crisp morning in January, and you stand at the entrance of your warehouse, eager to kick off another year of growth for your business. The dawn of a new year is the perfect opportunity to reflect on past achievements and set the stage for transformative changes. As the world of logistics and warehousing continues to evolve at a rapid pace, it is our firm belief that the resolution for 2024 should be to embrace smart strategies for a smarter warehouse. Let’s delve into the 4 key trends, backed by compelling statistics, that are reshaping the landscape for warehouse managers, logistics professionals, 3PL managers, Ecommerce Managers, Fulfillment Managers and many others engaged in supply chain.

Embracing Automation and Robotics

In a recent study conducted by Statista, the global warehouse automation market was valued at over 23 billion U.S. dollars in 2023. It is expected that the market will grow at a CAGR of about 15 percent in the following years and reach the size of 41 billion U.S. dollars in 2027, a testament to the accelerating demand for streamlined operations. As we bid farewell to static storage technologies, the emphasis on automation and robotics becomes paramount. By integrating Automated Guided Vehicles (AGVs) and Autonomous Mobile Robots (AMRs) into your warehouse fleet, you not only boost efficiency but also enhance the overall safety of your team. These technologies offer a dynamic solution for material handling, allowing for swift adaptability to changing demands.

AMR Autonomous Mobile Robot Handling Pallets

Picking Technologies that Redefine Speed and Accuracy

Accurate and speedy order fulfillment is the cornerstone of customer satisfaction, and in the evolving landscape of ecommerce, these two aspects of supply chain have become non-negotiable. According to a report by McKinsey, warehouses equipped with advanced state-of-the-art picking technologies experience a 20% increase in order accuracy. Imagine the impact on your bottom line when every package is delivered correctly the first time. Modern solutions, such as advanced Pick-to-Light technology and Pick/Put Walls, are reshaping the picking process, reducing errors, and ensuring your customers receive their orders promptly and accurately.

Fast Fetch Pick to Light / Put to Light / Pick Wall

Responsive Warehousing in the Age of Ecommerce

In the era of one-click shopping and next-day delivery expectations, responsiveness is a key differentiator for warehouse managers. A study by Deloitte highlights that companies with highly responsive supply chains grow revenue 10% faster and reduce costs by 30% more than their peers. This New Year, consider the implementation of Automation and Robotics, combined with appropriate Warehouse Execution Systems (WES) that can seamlessly integrate with your existing infrastructure, optimizing task prioritization, resource allocation, and order fulfillment. Responsive warehouses not only meet customer expectations but also stay ahead of market trends.

Optimizing Footprint and Reducing Costs

An increase in order volume or expansion of operations and SKUs, often prompts the need for more warehouse space. However, since warehouse space has been at a premium for some time now, the resolution for 2024 is to optimize within your existing footprint. By reassessing and redesigning your current layout, as well as deploying new solutions like high-density automated storage systems, you can maximize vertical space and reduce the need for extensive horizontal expansion. This strategic approach not only curtails costs associated with additional square footage but also enhances overall operational efficiency.

Automated Storage and Retrieval System

Conclusion

As you embark on this journey to build a smarter warehouse in 2024, remember that the right partner can make all the difference. ABCO Systems is a material handling integrator company with a proven record of incorporating cutting-edge automation, robotics, and picking technologies, thereby empowering your team to achieve higher accuracy, responsiveness, and growth – all within your existing footprint. Make this New Year resolution not just a commitment to change but a promise to revolutionize your warehouse for sustained success. Here’s to a year of smart strategies and smarter warehouses!

A Complete Guide to Mezzanines & Catwalks

A Complete Guide to Mezzanines & Catwalks

People tend to call any elevated platform a “mezzanine” these days, but that can be a big mistake, especially in the permitting process. The terms equipment (or work) platform and mezzanine both refer to structures that create an intermediate floor. There are some important nuances however, and whether you call a structure a mezzanine or an equipment platform can have serious implications when it comes to the ease of getting building permits, as well as construction costs. The impact on your taxes and depreciation will also vary depending on the term used.

What’s a warehouse mezzanine? What’s a work platform?

A mezzanine is a relatively permanent structure that is typically installed within an existing building or industrial facility. It is a raised platform that is constructed above the ground floor, typically supported by existing columns or posts, and is designed to provide additional floor space for storage, office space, or other purposes. Mezzanines can be designed and installed in a wide range of configurations to meet the specific needs of the facility.

Multilevel Pick Module

A warehouse platform, on the other hand, is a raised platform that is typically designed and constructed as a stand-alone structure with the aim to provide additional floor space for storage, manufacturing, or other industrial processes. Warehouse platforms are generally larger and more robust than mezzanines and are designed to support heavy loads and equipment.

The pivotal differences: Is it part of the facility? What will you be using it for?

The critical distinction lies in the platform’s association with the facility. It hinges on whether the authorities classify the mezzanine as an integral part of the building or as capital equipment. Numerous newly constructed buildings incorporate what they refer to as “mezzanine levels” into their structural design. When a platform is deemed an inherent component of a building rather than capital equipment, it may be subject to compliance with building codes, restroom requirements, accessibility standards, and may influence tax rates and depreciation schedules.

Another key factor is the intent – It is imperative to ensure that building permit authorities and regulatory bodies fully grasp the purpose and design of the structure. To achieve this, it’s advisable to refer to your mezzanine project using designations such as “work platforms,” “elevated platforms,” “storage platforms,” “equipment platforms,” etc. These terms offer greater precision and clarity compared to the overly encompassing and sometimes imprecise term “mezzanine.”

This can impact your taxes since in some states mezzanines are considered part of the square footage of the facility, while platforms aren’t. This can seriously impact on property taxes every year, as well as depreciation deductions since capital equipment depreciates differently.

Practical Applications

Combined with various warehouse automation equipment, mezzanines can provide a great option to grow in your existing footprint by optimal usage of the cube in a variety of applications:

  • Storage
  • Production
  • Offices/Administrative Space
  • Equipment positioning
  • Picking Modules

Utilizing the vertical space with a mezzanine means that you need to move material between levels without creating bottlenecks. This means that you will need automation equipment to move materials up and down between levels. The technology for this purpose can be grouped into 3 general categories:

  1. Spiral Conveyors. This type of conveyor has a small footprint and provides excellent throughput, usually for handling of cartons, totes and less than pallet loads.Pick Module with slat conveyors, belt conveyors and roller conveyors
  2. Incline Conveyors. Though it is less space efficient than spiral conveyors, the incline conveyor is a very economical and robust option for automated handling of a wide variety of loads.
  3. Vertical Lifts. These sturdy pieces of equipment have a small footprint and are particularly effective in setups where heavier loads or bulky items need to be lifted.

In a warehouse environment one of the most important advantages of elevated platforms is their high-density storage application. Generally speaking, these can be classified in 3 groups:

  1. Rack Supported Mezzanines. These mezzanine configurations combine high bay pallet racking with walkways between the rack. The racks can be fitted with carton flow for dense order picking and mixed storage of pallets. Rack supported mezzanines allow a multitude of options for customization and are a very economical choice for vertical space utilization.Shelving Mezzanine
  2. Shelving Mezzanines. Applied in configurations for handling small items such as parts or tools. This type of platform maximizes the number of storage bins, allowing for a great number of SKUs to be organized in a concentrated space while remaining easily accessible for pickers.
  3. Multilevel Pick Modules. These highly customizable solutions integrate various storage solutions that enable a very efficient movement of product by combining elements of mezzanines with conveyors, spirals, pallet/carton flow, static racking and shelving, pick/put to light etc. They are specially designed with zoning and provide significant cost savings for broken pallet, full-case or open-carton picking.

How we can help you

The choice between a mezzanine and a warehouse platform ultimately depends on the specific needs of the facility and the goals of the business. As a true systems integrator, ABCO Systems also has a vast experience in designing and delivering these kinds of solutions, including a very efficient navigation of the permitting process. Reach out to us today to get started!

Choosing the Right Conveyor System for Your Warehouse

Conveyor systems have become a staple of modern warehousing operations. These mechanical marvels play a pivotal role in efficiently and swiftly moving goods, enhancing productivity, and ensuring seamless and safe material handling. Whether you’re dealing with a large-scale distribution center or a smaller storage facility, selecting the right conveyor system is a critical decision. In this blog post, we’ll explore the types of conveyor systems and discuss their key benefits, shedding light on their technology and practical applications.

Key Benefits of Conveyor Systems

Productivity and Speed of Movement

Conveyor systems accelerate the movement of goods within a warehouse, resulting in faster throughput and order fulfillment. They maintain a consistent pace, minimizing bottlenecks and ensuring a smooth flow of products.

Efficiency and Flexibility

Conveyor systems enhance warehouse efficiency by automating material handling processes thereby reducing labor costs. They also offer flexibility in routing, sorting, and handling various items, enabling quick adaptations to changing operational needs.

Safety

Safety is paramount in any warehouse setting. Conveyor systems are designed with safety features, reducing the risk of accidents and injuries associated with manual handling. They help maintain a safe working environment for employees.

Types of Conveyor Systems

Belt Conveyors:

Technology: Belt conveyors use continuous belts made of rubber, plastic, or fabric to transport items. They run on pulleys or drive units.
Application: Ideal for transporting bulk materials, packages, and irregularly shaped items. Commonly used in distribution centers, airports, retail, and manufacturing facilities.

Pick Module with slat conveyors, belt conveyors and roller conveyors

Roller Conveyors:

Technology: Roller conveyors use cylindrical rollers to move items. They can be motorized or gravity-based, providing flexibility in operation.
Application: Suited for light to medium heavy items. They are commonly found in distribution centers, warehouses, and assembly lines.

Chain Conveyors:

Technology: Chain conveyors use interlinked chains to move products. They can handle heavy loads and are powered by electric motors.
Application: Ideal for moving pallets or heavy products in warehouses and distribution centers, as well as in industries like automotive, construction, and food processing.

Slat Conveyors:

Technology: Slat conveyors consist of slats or plates connected to a chain. They are designed for handling heavy and temperature specific items.
Application: Commonly used in heavier industrial facilities for transporting heavy or hot items.

Overhead Conveyors:

Technology: Overhead conveyors use a track system with suspended hooks, carriers, or trolleys to move items above the workspace.
Application: Suitable for painting lines, assembly lines, and storage facilities, particularly in cases where floor space is limited.

Key Considerations when Choosing a Conveyor System

 

When selecting a conveyor system for your warehouse, it’s crucial to consider a range of factors that will impact its effectiveness. Here’s a list of key considerations in bullet point format:

Conveyor sorter with gravity roller conveyors

Type of Goods/Materials to be Handled

Different conveyor systems are designed to handle specific types of goods. Consider whether you’re transporting boxes, pallets, irregularly shaped items, or even delicate or fragile materials. The choice of conveyor should align with the nature of your products.

Throughput

Determine the volume of items your conveyor system needs to handle within a given timeframe. High-throughput operations require robust systems to prevent bottlenecks, while low-throughput setups may benefit from more cost-effective solutions.

Available Space

The layout of your warehouse and the space available for conveyor installation are critical. Some conveyor types may require more floor space, while others can utilize vertical space effectively. Ensuring that the system fits seamlessly within your facility and optimally uses the available vertical space is very important.

Budget and ROI

Establish a clear budget for your conveyor system. Costs may vary significantly depending on the conveyor type, technology, and additional features. Balancing your budget with your operational needs is essential. On the other hand, automated systems reduce the need for manual labor, so calculating the ROI on your investment provides insights into the overall benefits of the implemented solution.

Scalability to Cover Long-Term Goals

Consider the future of your business and warehouse operations. A conveyor system should be scalable to accommodate growth and evolving requirements. Analyze the ease with which you can adapt, expand, modify, or reconfigure the system to meet long-term goals.

By carefully evaluating these considerations, you can make an informed decision and select a conveyor system that aligns with your specific needs, maximizes efficiency, and supports your warehouse’s growth and success.

At ABCO Systems, we understand the significance of choosing the right conveyor system for your warehouse. With decades of experience in consultancy, design, and installation of conveyor systems of all types and sizes, we’ve helped countless businesses achieve efficient and seamless material handling. But our commitment doesn’t end there. We go the extra mile by offering comprehensive preventative maintenance and servicing program to protect your investment and optimize your operations for years to come. Reach out to us today to explore the ideal conveyor solution for your specific needs and let ABCO Systems be a trusted partner in your journey to a more efficient and productive warehouse!

Beyond Racking: Unveiling High-Density Storage Solutions

Beyond Racking: Unveiling High-Density Storage Solutions

In the world of modern warehousing, the demand for optimized space utilization is a constant challenge. Traditional racking systems have long been the mainstay in the warehousing industry, providing reliable and robust storage solutions. However, as operational demands surge and available space is at a premium, the quest for more space-efficient solutions becomes imperative. High-density storage technologies offer an array of solutions for businesses seeking to maximize their warehousing operations. In this blogpost, we delve deeper into the subject of high-density storage, revealing its potential to revolutionize your processes.

The Dilemma of Space and Efficiency

Efficiency and space utilization are integral elements of warehousing success. High-density storage solutions offer the elusive answer to this space-efficiency conundrum. These innovative systems are meticulously designed to do more than merely expand capacity; they also prioritize accessibility, organization, and efficiency.

Pushback Racking: Dynamic Optimization

Among the unsung heroes of high-density storage is pushback racking. Distinct from traditional pallet racking, pushback systems permit multiple pallets to be stored within a single lane. This dynamic storage system hinges on specially designed carts and rails that facilitate the sliding of pallets into the system as new ones are loaded. It not only optimizes space, but it also significantly enhances accessibility, making it an adaptable choice for high-velocity goods.

Pallet Shuttle

Pallet Shuttle Systems: Efficiency Redefined

Pallet shuttle systems represent another hidden gem within high-density storage, offering an efficient and cost-effective way to store large quantities of goods. These systems employ motorized shuttles that transport pallets within deep storage lanes. By eliminating the need for forklifts to enter the storage lanes, shuttle systems save time, reduce labor costs, and dramatically optimize the warehousing operations. These systems are also configurable and customizable, allowing users to tailor them to their specific needs. They can be used in a variety of applications and are designed to be compatible with existing racking and shelving, making them an ideal solution for those looking to upgrade their existing storage solutions.

Very Narrow Aisle System

Very Narrow Aisle (VNA) Solutions: Precision in Cramped Quarters

For situations where every inch of space is critical, Very Narrow Aisle (VNA) solutions provide an answer. These systems, coupled with specialized turret forklifts, function in aisles that are substantially narrower than those required by traditional racking systems. VNA designs make optimal use of vertical space while ensuring that each pallet position remains easily accessible. They represent the ultimate choice for those seeking to optimize storage within tight confines and make the most out of the available warehouse square footage.

Automated Storage and Retrieval System

Automated Retrieval: The Fusion of Precision and Speed

To harness the full potential of high-density storage, automation is the key. Automated storage and retrieval systems (AS/RS) work seamlessly with high-density storage solutions, delivering unparalleled precision and speed. These systems transport products directly to operators, eliminating the need for manual retrieval. AS/RS systems are highly efficient and reliable, allowing for rapid product movement and provide the ability to respond to orders faster and in a more cost-effective way.

The automation of storage and retrieval processes also offers distinct advantages when it comes to inventory management. Automation means that products can be tracked extremely accurately as they move through the warehouse, providing real-time visibility into inventory levels. This allows companies to react quickly to changes in demand, ensuring that they always have the right amount of stock on hand, while achieving unparalleled accuracy and speed when handling the inventory.

 

The Route to Space Optimization

High-density storage solutions can be your gateway to space optimization and heightened efficiency. By embracing these innovative systems, you open the door to a more organized, streamlined, and cost-effective warehousing operation. Here are several tips to set you on the path:

Assess Your Needs: Commence by evaluating your current storage requirements and the constraints of your warehousing space. This initial step will help you ascertain the specific high-density solution that best aligns with your demands.

Seek Expert Guidance: High-density storage is not a one-size-fits-all remedy. Collaborate with experts who possess a comprehensive understanding of your industry and its unique challenges. Their expertise can be invaluable in designing a tailored solution.

Plan for Growth: Ensure that the high-density solution you choose can accommodate your projected growth. High-density storage represents an investment in your future, one that should be scalable to meet your evolving needs.

Invest in Employee Training: Implement comprehensive training programs to ensure that your employees are well-versed in the new system. Proper training will result in safer and more efficient operations.

Establish a Maintenance Routine: High-density storage solutions, like any other machinery, necessitate regular maintenance. Develop a schedule for routine maintenance to ensure your system operates at its optimal performance level.

The potential for more efficient, organized, and space-optimized warehousing operations is within reach. By partnering with ABCO, you can explore a world beyond traditional racking and position your business for growth and success even in the challenging landscape of economic uncertainty. Reach out to us today to get started!

 

Increasing Storage Capacity with Selective Racking

Increasing Storage Capacity with Selective Racking

Selective pallet racking is the most common pallet racking system. It is a storage solution for many warehouses and distribution centers. What makes it “selective” is that the user has direct access to every single pallet.
Selective racking is made up of uprights and beams, and pallets sit on crossbars. Wire decks can be used to help catch loose items from pallets or create locations to place cartons.

Advantages of Selective Racking

As stated above, an advantage for selective racking is that the operator has access to every single pallet. Unlike other pallet racking options, an operator does not have to remove pallets to gain access to a pallet, as selective racking is a first-in, first-out (FIFO) inventory system.
Selective racking is generally considered a less expensive option compared to other systems such as carton flow and push back racking.
Selective racking can be integrated with other forms of racking and material handling solutions to accomplish your goals within a DC. It is adaptable to any product size and weight and can be easily reconfigured for new product requirements.

Disadvantages of Selective Racking

A common disadvantage of selective racking is that it is considered a low-density storage and requires aisle spacing to ensure selectability. Aisle spacing is determined by the forklift in use at any given facility. Sit-down forklifts will typically require a 12ft aisle in between selective rows, while stand-ups require less.

Types of Lift Trucks

source: Cisco-Eagle

Selective rows can be installed back-to-back to ensure that the maximum space is being utilized in a warehouse.

Types of Selective Racking

Selective rack is available in both roll-form and structural steel.
Structural steel racking can support more pounds-per-square-inch than roll form. It is also very resilient and can withstand impact from lift equipment. The higher cost of structural steel might make it worth it if you are consistently needing to replace damaged uprights due to collisions by your forklift operators. Structural rack may also be a better option for food grade-product and cold storage applications.
Roll-form rack is made of a lighter gauge steel and is less expensive than structural. This type of rack is also easier to reconfigure and relocate within a facility.

Manufacturers for Selective Racking

Interlake Mecalux is ABCO’s primary partner manufacturer for selective racking. Their frames come in either bolted or welded variants, and they use high-strength steel to ensure your specifications can be met.
Contact ABCO Systems today to discuss a selective racking solution that works for your distribution center.

Improved Efficiency and Cost Savings with Warehouse Automation

Improved Efficiency and Cost Savings with Warehouse Automation

In the ever-changing world of supply chain management, warehouse automation is a key factor in ensuring that an operation runs effectively and efficiently. Batch picking and automated sorting are two technologies that can help reduce costs and improve accuracy in your warehouse. Let’s take a closer look at how these systems work and why they should be part of your warehousing strategy.

Batch Picking

Batch picking is a process that combines orders into batches before they are picked from the shelves. This system reduces the number of trips to the shelves required to fill orders, which increases efficiency while minimizing errors. The process starts with order consolidation software that looks at incoming orders and consolidates them into batches based on common elements like customer or ship-to location, product type, or order size. Once orders are consolidated into batches, pickers move through each batch in sequence to pick items quickly and accurately.

Automated Sorting Systems

Automated sorting systems are used to optimize the storage capacity of warehouses as well as streamline outbound processes. These systems use algorithms to determine which products should be stored where in order to maximize space utilization, minimize handling time, and increase throughput times for outgoing orders. Automated sorting systems are also capable of automatically routing products based on their destination or other criteria, allowing for greater flexibility in managing inventory flow within a facility.

As warehouses become more complex and operations become more demanding, technologies like batch picking and automated sorting can help you stay ahead of the competition by improving efficiency and reducing costs. By implementing these solutions now, you can ensure that you have an efficient warehouse operation today so you can remain competitive tomorrow. ABCO Systems will make the most of your batch picking by integrating with the right automation solution.  Supply chain professionals who want to optimize their operations should seriously consider investing in these tools – it could pay off big in the long run! CONTACT US to speak to an ABCO Team member about the right solution for you.

*Header picture depicts&OPEX® Sure Sort®