Three Mistakes That Impede Your Flow Rack Performance

Today, warehouse managers are always seeking ways to make their operations more efficient. Ineffective operations can have a negative impact on the company’s bottom line, customer satisfaction, workplace safety, and more. The good news is that there are many storage systems that warehouses can use to streamline their operations, such as industrial flow racks.

Flow racks are a high-density storage system that can be integrated into your warehouse operations to maximize space and enable FIFO (First In, First Out) product rotation. However, with the variety of styles and sizes available, finding the right fit for your operation can be a challenge.

Three Common Flow Rack Implementation Mistakes

Careful planning and consideration are essential for the successful implementation of flow racks. Errors in the selection, installation, and configuration of these systems can greatly hinder performance and operational efficiency. Here are three prevalent mistakes in flow rack implementation and how to prevent them from happening, so you can help ensure your warehouse or facility is working at peak efficiency.

1. Selecting an Inappropriate Flow Rack Track Width

Selecting the appropriate track width is key for preserving operational efficiency and optimizing space utilization. Choosing the wrong width can result in various issues that impede productivity and squander valuable space.

• Wasted Space: When items are smaller than the track they are placed on, it leads to inefficient use of horizontal space. This not only decreases the total storage capacity but also reduces the effectiveness of the storage system.
• Operational Issues: Inaccurate track width may hinder workers from arranging SKUs in the best position, resulting in inefficiencies during the picking process. When the track width exceeds the optimal size for the SKU, it produces gaps and complicates workers’ quick and safe retrieval of items. On the other hand, if the track width is too narrow, it can lead to product jams and improper fitting.

2. Not Enough Space Between SKUs

Many distribution facilities and warehouses don’t account for the amount of space they leave between SKUs, which can be incredibly detrimental to your operations. The ideal space between boxes is around 2 inches. This spacing maximizes your horizontal storage, ensuring that there is sufficient room for workers to pick up boxes using their sides. Spacing matters because if the boxes are too close together, it’ll be difficult for your workers to pick. Conversely, if the boxes are too far apart, it results in wasted horizontal space.

3. Selecting an Inappropriate Track Style for Your Flow Racks

Choosing the right type of track for your flow rack system is essential for maximizing efficiency. Flow rack systems primarily use two types of tracks: dedicated lane tracks and universal bed tracks, each with distinct features suitable for specific purposes.

• Universal Bed Tracks: Universal flow rack tracks are created for flexibility, which makes them appropriate for a range of box sizes. This type of flow rack track is ideal for situations where box sizes can be unpredictable. A good example is when you’re dealing with imported goods and packaging varies. Universal bed tracks are also beneficial for businesses with high seasonality that frequently rearrange SKUs based on throughput, as they can easily adjust to different types of products.
• Dedicated Lane Tracks: These tracks use carton flow rollers and are perfect for facilities with consistent box sizes. The separate lanes ensure that each type of box moves smoothly and is easily accessible.

Picking an inappropriate track style for your business can cause inefficient processes and unused space. For example, using dedicated lane tracks in a setting with unpredictable box sizes may lead to decreased storage efficiency. This mismatch not only impedes productivity but also impacts your bottom line by limiting the amount of space on hand.

Boost Your Operation’s Efficiency with UNEX Flow Products

When industrial flow racks are carefully planned and set up, they can enhance space utilization by as much as 50% without the need to expand the current storage area. FlexMation assists warehouses in unlocking this space potential through dynamic storage and carton flow systems from UNEX.

UNEX FlowCell

This dynamic, modular storage system was created to cater to your warehouse or facility’s needs. They’re durable, flexible, and uphold Lean guidelines by keeping your inventory organized. Benefits include:

• Enhanced Ergonomics
• Boosted Productivity
• More Versatility

Warehouses can depend on FlowCell for an extended period of time due to its 7-year warranty. Plus, FlowCell is 13x more durable than the average tube and joint modular structure, with the ability to support up to 1,000 pounds per level.

UNEX Gravity Flow Racks

UNEX flow racks provide seamless carton flow, allowing warehouses to make the most of their efficiency. These ready-to-use gravity flow racks maximize efficiency, prioritize safety, and optimize FIFO rotation. They’re perfect for facilities that require carton flow and don’t need to store pallets above the rack. Benefits of UNEX Roller Racks include:

• Denser Storage
• Easy to Install and Use
• Limits Worker Strain

The modular design of UNEX Roller Racks lets you adjust storage capacity easily by adding or removing rack sections as needed. Racks can also be restructured with different carton flow lane styles to meet your evolving inventory demands.

Optimize Warehouse Flow with Help from FlexMation

Maximizing space is important for any manufacturing environment. One of the best ways to achieve that goal is by using flow racks to organize important components in your warehouse. Curious if UNEX roller racks are a good fit for your industrial needs? Unsure whether you’re implementing flow racks correctly? Contact FlexMation today. Whatever your goal, our team of experts will help you get there.