Solve Material Shortages – Creative Pallet Rack Solutions to Tackle An Unpredictable Supply Chain

How Increased Safety Stock Can Help You Avoid Production & Fulfillment Shutdowns 

Manufacturing and distribution centers depend on a steady and reliable supply chain to deliver domestic and imported products. When unexpected disruptions like we’ve experienced recently hit the supply chain and impede shipments, they can have a dramatic and damaging impact on your business.

Most businesses and consumers have felt the impact of the global supply chain shut-downs and shortages. The ramifications of the disruptions are far-reaching due to the interconnectivity of the supplier network. For example:

• An overseas container bound for the US waits for cargo for 10+ weeks vs. 3 due to raw material and manufacturing backlogs.
• Containers arrive at the US destination ports and again sit due to dock labor shortages and transportation bottlenecks.
• Wholesalers have to update retailers and parse out which of their customers get what and when. 
• Retailers must provide up-to-date inventory information to consumers… many of whom have moved to online shopping… while at the same time stocking brick and mortar facilities with enough stock to satisfy walk-in customers.
• Customers choose between waiting for an item from a favorite supplier or bouncing to another source that says they can provide the item faster.

In a smooth running supply chain, everyone along the chain is better positioned to receive the item they desire at the time they need it, but today things are different. 

With so much of the supply chain challenges out of your control, one of the best safeguards you can have is a supply of “safety stock”. Safety stock is extra inventory over and above what you would need for normal day-to-day operations. Safety stock is a hedge against supply chain slowdowns but will cost you warehouse space; however, with the right approach, you can manage both the additional inventory and still optimize your available space. 

Storage Rack to Suit All Your Inventory Optimization Needs

We offer a variety of scalable racking solutions, no matter what your facility’s size or output needs may be, including:

Selective Pallet Racking – Turn unused or underused square footage into productive, highly-organized pallet rack storage. Selective pallet rack allows operators to select any pallet load from the pallet racking system without having to move any other pallets. 

• Advantages –  Selective pallet racking is easy to install and allows you to store pallets vertically for maximum space optimization.  Selective pallet rack also offers complete SKU selectivity but limits storage capacity to one pallet deep. This does, however, allow for direct access to each pallet, which makes them ideal for FIFO selection. 

Push-Back Racking – Get the best of both worlds! Push-back racking offers a high-density storage push-back rack combined with 100% SKU selectivity by lane. In a push-back racking system, pallets are stored on carts with wheels that rest on rails that are slanted toward the front of the pick face. The pallet being unloaded keeps the ones behind it in place. When it’s empty, gravity pushes the pallets toward the front. Push-back racking is designed using a single-aisle for loading and picking, minimizing square footage needed while maximizing pallet storage. It is ideal for high-volume, multi-SKU applications.

• Advantages – Push-back allows you to make the best use of your storage space while optimizing selectivity. Pallets are stored two to six deep, allowing for quick accessibility coupled with high-density storage… the best of both worlds! As a dynamic storage solution, push-back provides reserve pallet storage and an automatically replenished pick face.

Pallet Flow Racking – Achieve highly efficient, space-saving pallet rack storage with gravity-fed pallet flow rack. In pallet flow racking, pallets are placed on wheeled or roller lanes and gravity moves them toward the front of the system. Pallet flow is a perfect option for shifting inventory needs when you’re at the mercy of an erratic and unpredictable supply chain.  Quickly rotate perishable goods, seasonal items, or other time-sensitive products. 

• Advantages – Pallet flow racks offer deep lane and very-deep lane (2-20+ pallets deep) dense storage to be able to respond to inventory level shifts and back stocking needs which can be sparked by supply-chain disruptions. They also combine high selectivity with high-density storage capabilities and can be designed to accommodate pallets of all shapes and sizes.

Carton Flow – Achieving fast and accurate order fulfillment is the name of the game today when a competing product is just a mouse click away. Carton flow rack can help you ensure accurate picks and quick order processing with room for a constant supply of ready-reserve stock. 

• Advantages – Carton flow offers benefits over static shelving or broken case picking from a pallet by condensing SKUs into ergonomic positions in racking. Carton flow organizes SKU lanes so that each pick is not only fast and accurate but the pick face is replenished automatically. Reserve stock is always at the ready. Also, loading inventory from a rear aisle minimizes congestion in the pick aisle.  Package and tote flow racks are available with full roller style or skate wheel depending on the package weight and application.

High-Density Pallet Flow

Carton Flow Rack

Drive-In Racking – Gain deep storage of same SKU pallets in a condensed space with drive-in rack.  Structural and roll form rack construction is available. For high forklift and PIV traffic areas, structural rack offers additional protection from damage.  Forklifts drive into the lane to deposit pallets on rails that run upwards of 10 pallets deep. The first pallet is loaded in the farthest pallet position in the lane with subsequent pallets to follow until the lane is full. The last pallet in is the first pallet picked for last-in/first-out inventory rotation. 

• Advantages – Drive-in pallet rack offers more storage density than selective racking, requiring less aisle space and more configuration options for pallets. Drive-In is limited to LIFO inventory configuration.

Mobile Aisle Storage –  Eliminate the need for fixed aisles and consolidate your storage space. Mobile aisle storage allows you to condense your storage space into a centralized, easily accessible area. 

• Advantages – Mobile aisle storage eliminates the need for fixed aisle space and provides high-density storage solutions mounted to carriage or rail systems. They maximize space and create instant movable aisle racks to accommodate fluctuating inventory storage needs brought about by supply chain changes. 

Cantilever Racking – Organize and consolidate all your bulky, long, awkwardly shaped, and non-palletized inventory with cantilever racking.  

• Advantages – This system is designed to be easy to reconfigure to accommodate more or varying product storage Cantilever rack systems can help you quickly react to fluctuating inventory levels while ensuring inventory is well organized to meet pick accuracy goals. Ideal for construction supplies, piping, furniture, carpeting, and similar bulky inventory.

Pick Modules – Maximize storage capacity and bolster your efficiency in both cases and each picking.  Pick modules provide high-density storage using a combination of various racking solutions usually integrated with conveyors. Shelving, Speedcell bin systems, and carton flow racks are typically used to store SKU’s for supermarket-style picking operations.  Pick modules can be utilized without expansion and time-consuming building expansion.  Often freight elevators (VRC’s) are integrated into pick modules to transport pallets and bulk material. When it comes to supply chain disruption, pick modules can be assembled to accommodate the immediate processing of items or to prioritize SKU selectivity for expedited order fulfillment. 

• Advantages – Pick modules can combine many different kinds of storage systems, including pallet flow rack, carton flow rack, static storage rack, push-back rack, shelving, and more. They can be configured on the warehouse floor level or above as part of a mezzanine to take advantage of vertical warehouse space. Typically they are paired with conveyor systems to streamline and expedite order fulfillment. 

Let WOI Help You Navigate Supply Chain Disruptions 

Supply chain disruptions may be a fact of life for the foreseeable future. Let Warehouse Optimizers, Inc. (WOI) help ensure your business is ready to navigate the rough seas ahead with ample storage solutions and operational efficiency.

Our expert team will conduct a thorough site inspection and design the best options for you and your team to succeed. With our 5-Step Total Satisfaction Experience™, WOI guarantees that we will 1. Listen to your needs, 2. Execute your project with particular attention to your unique application, 3. Stick to project timelines, 4. Ensure a safe environment, and 5. Finally, pay close attention to the appearance of the finished product. The WOI team will walk you through each stage of the process and provide expert customer service to deliver outstanding results and peace of mind. 

Contact a member of our team today, and let’s set up an on-site visit or Zoom. Call (865) 540-4004 for a prompt response. We proudly serve customers throughout the Southeast, including KENTUCKY, TENNESSEE, NORTH CAROLINA, ALABAMA, AND FLORIDA.