- Automated Distribution Center
Our team assisted with the development of a new distribution center at a manufacturing plant. The facility produces a wide range of bathroom fixtures and accessories. The client had developed an initial 350,000-square-foot warehouse layout using conventional racking and material movement employing fork trucks to manage growth through end of 2018.
After reviewing the production data and forecasted growth, we suggested an automated warehouse solution. The initial design of the automated system showed a required footprint reduction of 225,000 square feet. This was accomplished by taking advantage of the available cube space and designing the warehouse to a height of 110 feet. Using this tall dense storage model, the team could accommodate approximately 24,000 large pallet locations, which was greater than the original 350,000-square-foot design and allowed for growth through 2021. The reduction in square footage offset much of the cost for the purchase of the automated equipment.
The automated system employs a warehouse management system that also manages all inventory in the warehouse. This includes first in first out (FIFO), expiration dates, lots and serialization, and accurate inventory counts. This automation also allowed for a 75 percent reduction in warehouse personnel, who were retrained and placed in other areas of the business.
In addition, the team designed automated material handling using automated guided vehicles to move finished goods from the production process to the warehouse. This reduced 80 percent of the manned fork truck traffic in the plant, which increased overall worker safety.
- Design-build project delivery
- Construction supervision service
- Project management
- Design management
- Pre-construction services
- Equipment procurement
- Construction administration