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5 DISASTROUS OUTCOMES OF BADLY PLANNED RACKING (AND HOW TO AVOID THEM)

5 DISASTROUS OUTCOMES OF BADLY PLANNED RACKING (AND HOW TO AVOID THEM)

5 DISASTROUS OUTCOMES OF BADLY PLANNED RACKING (AND HOW TO AVOID THEM)

If you’ve not seen any of the recent horror videos doing the rounds on social media, let us describe the scene: a vast warehouse with skyscraper-like racking suffers a cataclysmic collapse. Metal structures buckle under the weight of inventory and crash down with deafening force and - most scarily - only narrowly miss plucky warehouse staff below. 

Of course, these situations represent only the extreme end of the bad racking spectrum: the uncertified, under-spec'd racking that jeopardizes lives and livelihoods. The kind of shoddy solutions chosen by those happy to cut corners and gamble with safety. 

Happily, most warehouse managers understand the value of safety and efficiency, and seek to optimize their warehouse space without compromising on quality. For them, the true disaster lies in inefficiency - in investing time, money, and resources into a system that ultimately fails to deliver. This is the situation for many who, despite their good intentions, end up stuck with the results of badly informed decisions for the next three to seven years (the average time that growing  companies update their warehouse storage system).

The consequences can be severe: wasted space, squandered resources, and the lingering burden of an unfit system. 

In this blog, we're going to explore the various ways in which sub-par racking can jeopardize your entire operation. And fear not, we’ll also provide you with solutions to ensure your racking is always up to the job.

SAFETY HAZARDS

In extreme cases of sub-par racking there’s a significantly increased risk of accidents such as collapses, falls, and product damage. 

We firmly believe the most critical aspect of warehouse management is ensuring the safety of your employees and next, of course, your inventory. 

Poorly designed or improperly installed racking systems, as we’ve already seen, can pose significant safety hazards, including a risk to life. Such incidents not only endanger the long-term well-being of your workforce but can also result in costly downtime and liabilities.

Safety hazards due to poorly designed or imporperly installed racking system

WASTED SPACE

Using available warehouse space intelligently and efficiently is key to maximizing the storage capacity and ultimately the success of your warehouse and maximizing your return on investment. 

Neglecting to maximize the vertical space of your warehouse is a key space waste. Racking systems that are poorly designed can limit your ability to store and manage inventory effectively. 

These inefficiencies can result in overcrowded aisles and shoddy picking processes, which ultimately reduce productivity and profitability for your business. At the extreme, we’ve seen badly planned racking standing empty in a busy and overflowing warehouse as it just doesn’t suit the inventory and material handling equipment in use!

Wasted space in warehouses

COMPROMISED INVENTORY ACCURACY

In warehouses serving industries such as food, manufacturing, and pharmaceuticals maintaining the integrity of inventory is paramount. Badly recommended racking systems that don’t align with the inventory requirements can increase the risk of product spoilage, create extra work for forklift operators, and complicate inventory management. 

This of course can have far-reaching consequences, including inventory loss, customer dissatisfaction, and damage to your brand reputation.

OPERATIONAL DISRUPTION

The smooth operation of your warehouse relies on the seamless functioning of its infrastructure - in which pallet racking plays a lead role. 

Substandard racking solutions fail to deliver on the much-needed efficiency, leading to operational disruptions and delays in fulfilling orders. These interruptions not only impact your bottom line but can also result in missed deadlines, unhappy clients, and lost business opportunities.

COMPLIANCE ISSUES

As we all know, warehouses are subject to strict safety and compliance standards. 

Failure to adhere to them can result in hefty fines, legal penalties, and even business closures. Opting to use  racking systems that are under-capacity or uncertified which do not meet industry standards and fail to comply with local regulations is a fool’s game and will expose your business to unnecessary risks and liabilities.

OUR PERSONAL EXPERIENCE WITH BADLY DESIGNED RACKING

Over to Meriton’s General Manager, Phil Anderson,  ‘A client on a high-value project had put out a tender for a racking solution that an engineering firm had designed for them. We reviewed the plans for the racking system and also visited the client’s business and studied their operation. What became clear was that the proposed racking plans and material handling equipment were really not the right solution to the client's needs. Inefficient, dangerous even. We were honest with the client about our concerns, and said, ‘We can’t quote you this racking system, it won't work for your business’ Instead, we said, ‘Here’s the problem and here’s how we could help you solve it.’ 

‘There are a lot of order-takers out there who will sell you racking but won’t put the time and effort in to understand your business and your needs and you won’t get the advice you need to make your move a success. Get your warehouse storage plan right and it’s going to deliver profit for the next ten years - get it wrong and it’s the opposite story. You have one chance to get it right, the first time, and we’re passionate about doing that for our clients. This particular client chose to work with us in the end - and we’re pleased to report the project was a success and the client was very happy with the efficiency once the new warehouse became operational"

TO SUM UP…

It’s plain to see that steering clear of badly planned, inefficient racking solutions is crucial for keeping both your team and your business on solid ground. By putting safety first, optimizing your space, ensuring inventory requirements are met, streamlining operations, and staying compliant, you're laying the groundwork for a warehouse that runs like a well-oiled machine. It's a challenge we confront head-on, guiding our clients away from the edge of disaster towards a future of seamless efficiency and sustainable success.

Meriton Industries Racking Solutions

Our advice? To avoid headaches down the road, take a proactive approach to quality-racking planning today. If you're feeling uncertain about your current racking situation or need a hand in upgrading to safer and more efficient solutions, our team is here for you every step of the way. Your warehouse's safety and success mean the world to us, too.

Get in touch with us today to find out more