Launching a new warehouse brings a number of challenges, from space design to technology implementation. Among the most common problems we see are inefficient use of space, confusion in inventory records, slow picking, and high operating costs.
Here is an overview of several specific problems and their solutions based on our experience:
1. Problems with space and layout (Layout)
Problem: Poorly designed aisles, unused vertical space (high warehouse but
low racks), chaotic placement of goods.
Solution: Analysis of goods flow: Design the warehouse so that goods move in one direction (receiving -> storage -> shipping).
Vertical storage: Utilize the height of the hall using pallet or cantilever racks.
VNA technology: For narrow
aisles, use handling equipment for very narrow aisles (Very Narrow Aisle), which will increase capacity by up to 25%.
2. Inaccurate inventory records and chaos
Problem: Lost items, discrepancies between PC records and reality, slow inventory.
Solution:
Introduction of WMS (Warehouse Management System): Warehouse management software that tracks the location of goods in real time.
Barcodes/RFID: Automation of receiving and dispatching using scanners, which eliminates human error.
ABC analysis: Place the most popular goods (A) closest to
shipping, less popular goods (C) further away.
3. Slow picking and order errors
Problem: Employees spend too much time walking around the warehouse, goods are mixed up during shipping.
Solution: Route optimization: WMS suggests the shortest route for
picking.
4. Labor shortage and low productivity
Problem: High turnover, slow training of new employees, physical demands.
Solution: Automation: Use of conveyors, automated guided vehicles (AGVs), or robotic arms (GOODS-TO-PERSON systems).
Ergonomics: Equipping packing stations to reduce physical strain (lifting tables).
5. Failure to cope with peaks (seasonality)
Problem: The warehouse collapses during seasonal sales (e.g., Christmas).
Solution: Flexible workforce: Hiring temporary workers and
training them quickly (WMS with intuitive controls makes this easier).
Cross-docking: Goods go straight from receiving to shipping without long storage.
6. Safety and legislation
Problem: Workplace accidents, non-compliance with standards, damage to racks.
Solution: Regular rack inspections: Marking the load capacity of racks with labels.
Training and protective elements: Marking aisles, protective barriers on rack columns.
The key to success is not to underestimate the preparatory phase (layout) and to invest in a suitable information
system (WMS) right from the start.
We are also able to provide technical supervision and communicate with the investor before and during the launch of a new warehouse or entire warehouse hub.