6 Tips For Maximizing Warehouse
And Production Space
The effective use of space in manufacturing and warehousing environments can have
a dramatic impact on your business. A well thought-out storage plan can maximize
the use of your facilities, increase productivity and efficiency and reduce workplace
stress and accidents. The following 6 tips should help you make the most of what
you've got.
TIP 1: Too Little Space
Too little space between production machines, storage units or walkways can decrease
productivity. Maneuvering power equipment in tight areas or accessing machinery
with little clearance will decrease the efficiency of operators and can even
lead to accidents. This may result in damage to products, walls, support structures
and equipment - not to mention employees! While one solution will not fit all
situations, there are a few industry guidelines. Walking aisles are normally
3' to 5' wide. Aisles for power equipment (such as fork lifts) are usually 5'
to 12' wide, and aisles where ladders are used are generally 3' to 6' wide.
TIP 2: Too Much Space
While it is important to have adequate clearance, too much space can also be
a problem. The most obvious, of course, is simply not being able to use this
open space for storage or production. If your warehouse has 10 aisles and each
aisle is 2' too wide, you have just lost 20' of additional space... maybe even
enough for another aisle. In addition, extra open space has a tendency to "collect" things.
This informal storage of items in extra-wide walkways can not only appear disorganized,
but can also lead to accidents and inefficiency.
TIP 3: Go Up
One vastly under-utilized area in most warehouses is the vertical area above
normal floor level. This air space is seldom used to its full potential. Vertical
space may be used by installing taller storage mediums or adding a mezzanine.
Mezzanines are, in essence, a partial second story in a segment of your open
space. Storage vendors offer complete mezzanine "kits" that can be
installed into existing space with minimal cost or trouble. They are a great
way to add additional work or storage area without adding square footage to
the building.
Mezzanines are available in many designs that minimize the impact to the area below, and layouts for mezzanines vary with the area available and the capacities required. In addition, most mezzanines can be removed and set-back up in another location. So you can get some extra space now without committing to having it there all the time... you can even take it with you when you move! As you plan to "go up" don't forget to take into account the space needed for access.
Mezzanines will require stairs, ladders and/or a lift, and taller storage units may require special equipment to access them. This may require more maneuvering room in the aisles below.
TIP 3: Instant Offices
Many businesses have trouble deciding on the right mix of office to warehouse
space. They may not need all their warehouse space today, but also do not want
to convert it permanently into offices.
One good solution is pre-engineered, modular offices. These are essentially configurable offices. The walls, ceilings and floors are all brought-in ready to install - complete with sound-proofing for a quiet office environment, appropriate lighting, power outlets and heating and air conditioning. It is even possible to add second stories and complete "buildings" using this modular construction. The initial costs are up to 35% less than traditional construction, and the flexibility is there to change the layout whenever you need it. In addition, modular offices are usually considered equipment (not permanent construction) and as such may provide tax advantages.
TIP 4: Storage Plan
Creating an overall plan with a facility layout is crucial to maximizing the
use of your facilities and minimizing accidents. You can create such a plan
yourself or seek an outside firm for assistance. Some storage vendors will help
you create such a plan and can offer solutions such as shelving, protective
guard rails and other items that make the most out of what you have.
TIP 5: Choose Wisely
If you do decide to hire an outside company to design a storage plan or even
just to purchase specific storage products, it is important that you select
the right vendor. A badly conceived storage plan can make matters worse, frustrate
employees and slow down production.
An appropriate plan can not only save you money, but increase your business productivity and employee safety. When considering a vendor, be sure to check references. Make sure they have created successful plans before. Also, choose a company that has experience installing the equipment they sell. They will have a better chance of helping you decide what will work and what won't if they have implemented similar solutions at other companies.
TIP 6: Relocation Help
One final tip. If you are in the process of relocating your facility, you may
wish to bring in a storage expert before you have finalized your warehouse space
plans. They may be able to help you envision how different properties may best
work for you. In addition, if you are going to rework your storage and production
areas, there is no easier time than during a move.
Almost everyone can agree that more efficient storage can dramatically improve a company's productivity; however, getting started can be a little intimidating. One of the easiest ways to tell if you have a problem is to walk and talk. First, walk the warehouse and production floor during a busy time of day and see how things are flowing.
- Do employees spend a lot of time searching for items?
- Do they seem to be getting in each other's way?
- Is there "stuff" stacked into corners and wide aisles?
- Are there any wide open areas not being used - even areas above your head?
Second, talk to your employees. They are in the warehouse environment every day. Ask them how they think things could move more smoothly. And third, consider calling in a storage expert to help you make the most of what you've got.
Industrial Properties Magazine - June 1999