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Warehouse Problems and Solutions

Warehouses are finding themselves in increasingly volatile situations as faraway events in the global supply chain have an impact on local firms. When dealing with these difficulties, the best solution for your warehouse’s lifespan and sustainability is to ensure that you have flexible and scalable systems in place that adhere to industry best practices.

1. Inventory Accuracy

Inaccurate inventory leads to issues such as maintaining inaccurate stock levels and stockpiles of obsolete inventory. Picking issues occur as a result of pickers relying on erroneous information, resulting in inefficient operations. Other consequences of faulty inventory include decreased productivity, greater expenses, and corresponding revenue loss.

Solution:

Craftsman’s Warehouse Management System (WMS) helps to automate data-recording processes, provides real-time and reliable information about stock levels and composition. The technology helps the user to visualize the pallet location, id, quantity and any other relevant data necessary for the ease of operations.

2. Space Utilization

Space utilization is a major success factor in warehousing. In warehouses with poor facility layouts, insufficient storage capacity and inefficient utilization of limited space are major challenges. Managers are concerned about unfavorable warehouse design because it has a direct correlation to a potential negative impact on profits. Furthermore, warehouses near population centers sometimes occupy the more expensive property, which raises prices.

Solution:

The optimal warehouse plan considers both the available floor area and the available vertical space. A good plan not only maximizes the use of space, but also the utilization of equipment and labor, accessibility to all goods, the security of all items, and the safety of workers. Stacker cranes help to achieve volumetric efficiency whereas conventional MHEs take up more horizontal and vertical area. Our Vertical storage system – Vstore saves the floor space up to 80% when compared to other static systems.

3. Redundant Activities

Many warehouses are plagued by unnecessary, excessive product handling, with cases or pallets being transferred through many intermediate locations. However, redundant actions are not always visible. Duplicate data entry and information duplication are two key time wasters.

Solution:

Our barcode reading technology in ASRS reduces the part details entry time and sends the input directly to IPC, thus improving the warehousing process by eliminating unnecessary operations and better user interface. Automated systems are continuously evolving, and are the worldwide trends to drive the process owners by keeping up-to-date technologies in order to quickly adapt and prosper, not just survive.

4. Labour Cost

Excellent warehouse managers try to maximize productivity while minimizing labor expenditures in a labor-intensive environment; these costs can account for up to 65 percent of most warehouses’ operating budgets. Warehouses typically use expensive equipment and big labor groups, posing a difficulty that is specific to warehousing operations.

Solution:

The “goods to person” strategy reduces the amount of time spent walking from one pick location to another within a warehouse. The two basic approaches to tackling labor-related issues are minimizing available labor and replacing labor with automated technology.

5. Quality Control

In many situations, staff in charge of quality control also pick, pack, and ship inventory products, therefore many errors go undetected until they reach the client. This is especially true in a pandemic setting, as warehouses are attempting to transport more with fewer personnel available.

A quality control feature can track vendor accuracy, increase stock rotation, and eliminate the requirement for manual warehouse processing. Quality control methods ensure that the rest of the warehouse management program works properly.

Solution:

Consider a holistic system with updated WMS technology to ensure the flexibility required to manage any storm. The more transparent and available your data is, the more you can decrease these risks and have a constant, trustworthy warehouse analysis methods in which staff and customers can find maximum efficiency and trust.

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