Intensive Storage Solutions-warehousing Problems And Solutions for Manufacturing

Problems faced by manufacturing today: large inventory but small spaces; The speed at which the parts, components and materials enter the warehouse is not equal to the speed at which they leave the warehouse, and that the speed at which the parts are taken out for production is not equal to the speed at which finished products leaves the operation area. 

Consequences from these problems

• Small storage space increases the storage cost.

• Inadequate inventory due to the small storage hamper manufactors' expanding scales to meet the surge demands in a certain season, pricing based on large inventory and predicating. 

• Conflict with the 5S Methodology, especially for the lean warehousing, failing to make the best plan for each production process and realize highly efficient repetitive work

Available solutions and problems related  

Problem: time-consuming and extremely costly. Manufacturers are faced with both the construction cost and the rising land cost, especially in growing urban centers.

Problem: 1.Increased transportation costs, damages to the product when loading, carrying and transporting, losses due to mistakes made by workers.

2.Dispatch delay

3.Limited by costs of land, labor and machine prices.

4.A part of the space should be put part for loading or carrying.

5.Additional workers are required for removal, while some incompetent workers may lower the removal efficiency.

Better utilization ofthe existing facilities

Conventional storage racks are limited not only by the height of the building but also by the maximum reach of the pickers and forklifts, which results in a lot of unused vertical space left.

Advantages:

1.Cost saving by taking full the original storage space and avoiding the construction of new facilities.

2.Reduce the cost of labor, plant and transport.

Disadvantages:

1.It is difficult to plan the use of the original facilities.

2.During the installation of smart devices, a temporary interruption of production or an alternative workaround process is required.

The radio shuttle racking system helps to make the best of the space to store as many products as possible. Thus, the radio shuttle racking system, taking up 40% smaller land, is the ideal choice for manufacturers with limited space. With the radio shuttle racking system, manufacturers can flexibly change the layout to meet certain requirements and put apart the space for other tasks at the same time. 

On-site storage allows for a more accurate release of stock to keep production lines running smoothly and efficiently. In addition, on-site storage helps to reduce the risks of damage and delay. Moreover, increasing the storage by taking full advantage of the existing space helps manufacturers to save the cost of constructing new buildings and extend the service life of the existing facilities.

How to realize the benefit of AS/RS in manufacturing  

1. The storage scheme is affected by practical uses, from the number and type of shuttles used to pick up the products to the height and spacing of the racks that can be adjusted by the shuttle. Manufacturers should assess the practicability of the complex and unique management.

2. Also, manufacturers should take SKU growth into consideration. SKU growth enforce manufacturers to manage larger and more diversified storage, which requires a special solution to provide adequate storage, flexible and quick access to keep production running smoothly and efficiently.

3. In addition, enterprises should take seasonal inventory changes into account. Some enterprises increase purchase volumes in order to price lower for their products during the peak season, however, this results in the severe imbalance of products coming into and coming out of the warehouse. Hence, they need a storage solution to provide adequate capacity and allow for flexible changes to keep production running smoothly.

4. Moreover, manufacturers should coordinate the coming in and coming out of different products. Evaluating the speed at which hot products leave the warehouse helps to plan for the location and quantity of such products. Frequently-used products are left in key areas for quick access, while seldom-used items can be stored elsewhere outside the shuttle system system.

5. Plan for the installation of smart equipment in advance in order that the plan can be scheduled in stages during the off-season. Or, adopt an alternative workaround. Rational arrangements help to minimize the disruption in production.