Setting Up a Warehouse Racking System
After selecting the appropriate racking system for your business, the next step is to arrange it for optimal efficiency, inventory management, bottleneck avoidance, and safety.
Key considerations for your warehouse racking include:
Spacing Between Racks
Ensure sufficient space between racks for easy access to materials. While it may be tempting to place racks close together to maximize floor space, this can hinder picking efficiency. Be mindful of pallet loading and picking points, especially with pushback or pallet flow racks.
Aisle Width
Aisles should be wide enough for material handling equipment like forklifts and pallet jacks to navigate safely and efficiently. For systems like double deep racking, consider placing racks back-to-back to conserve space while allowing for wider aisles.
Labeling & Organization
To enhance stowing and picking efficiency, implement a consistent organization system for your warehouse and inventory. Rather than organizing alphabetically or by SKU, consider grouping items commonly purchased together, seasonal products, and best-sellers in accessible locations. Clearly label each storage area and maintain a master list of products with their aisle numbers for pickers.
Layout of the System
When designing your warehouse layout, initially disregard any obstructions (e.g., columns, mezzanines, workbenches). After establishing a basic plan, incorporate these obstructions while minimizing changes. Longer rows of racks typically yield the most efficient layouts; include cross-aisles to facilitate easier movement between aisles.
Calculating Shelving Load
Before loading shelves, calculate the load capacity for each rack and display this information prominently. Overloading racks can lead to accidents, including falling pallets or rack collapse. Warehouse racks consist of vertical uprights and horizontal beams, which form the framework supported by additional components.
To determine shelving load capacity, consider various factors, including:
Upright Capacity: Influenced by the height, width, and spacing of uprights; wider spacing reduces weight capacity.
Beam Capacity: Affected by the depth-to-length ratio and the dimensions of each beam; longer, thinner beams hold less weight and may bow over time.
Height of Each Pallet Position: Higher levels hold less weight.
Number of Storage Levels: Higher levels reduce weight capacity.
Material Quality: Thickness and strength impact durability.
Refer to the manufacturer's load capacity chart, as capacities vary by model. Plan your inventory storage based on these calculations, ensuring you never exceed the rack's weight capacity and that the weight is uniformly distributed.
If your rack is adjustable, calculate the maximum total pallet weight it will hold and work with your installer to ensure the design accommodates this weight above the calculated capacity.
Warehouse Racking Systems and OSHA Inspections
While OSHA does not provide specific guidelines for racking safety, employers must ensure their systems do not pose hazards to workers.
