Seven solutions to Warehouse Issues

To outsiders, warehousing often looks straightforward — just store products on racks until they’re needed, but industry insiders can only wish it was that simple! 

Here’s a look at seven of the top warehouse problems and solutions to those problems that might help ease the load:

1.Inaccurate Inventory

Incomplete or inaccurate records often reveal themselves when a warehouse worker attempts to retrieve product from an expected location, and it is not there, or then they are directed to store product in a location that’s already full. 

Many of these issues result from less-than-optimal, burdensome manual processes that produce inaccurate data in the system. One solution is incorporating warehouse execution system (WES) applications and other systems that help automate data-recording activities.

 2. Redundant Activities

The existence of unnecessary, excessive handling of product plagues many warehouses, with cases or pallets being moved through several intermediate locations. 

What to do about it? Ask the team for ideas and, for a different perspective, consult with specialists in warehouse technology. A new layout might help, or maybe it’s time for investment in a modern WES.

 3. Suboptimal Picking

If picking isn’t done efficiently, obviously, time and money are wasted. Yet what does “efficient” look like? Ideally, picking minimizes time and movement, with the goal of maximizing units picked per hour. Warehouse automation can help with this by implementing automated retrieval and picking solution.

The solutions are to standardize processes, including pick routes, and invest in appropriate automation for data handling/inventory management.

 4. Poor Layout/Space Utilization

Achieving good space utilization has taken on new urgency with the rise of e-commerce. In fulfillment centers, there’s more movement and picking, increasing the cost of poor layout. 

Using a WES data to identify the most frequently picked items and then, rearranging storage locations to minimize distance traveled for picking these. Additionally, explore what new racking and storage technology could do to positively effect utilization. For example, a high-density automated storage and retrieval system (AS/RS) could significantly increase space utilization.

5. Seasonal Demands

How do you allocate space as workload varies seasonally? Configuring the warehouse for peak demand means potentially leaving areas underutilized the rest of the year.

Warehouse automation products offer solutions. Pallet flow systems, new racking, and more capable lift and boom trucks can also boost units per hour handled, as can a complete AS/RS. Increasing capacity this way provides “headroom” for the busy periods without saddling the operation with poor space utilization the rest of the year.

6. High Labor Costs

Managers at distribution and fulfillment centers are under increasing pressure to reduce costs while improving service levels.

Picking is still, for now, a highly manual task, although solutions continue to emerge. Consider how technology can increase pick rates and how pallet flow systems and AS/RS technology should be part of the solution.

7. Avoiding Product Damage

There are myriad of reasons that product can be damaged in a warehouse. Sometimes this is found during picking.

Modern racking and pallet flow systems can move product more carefully than older technology. Cases are decelerated and zero pressure systems maintain a minimum separation to prevent damages. AS/RS is, once again, another solution.