Selective Rack + Cantilever Rack for Large Range of SKUs – A Case Study

Solution at a Glance

• Services Provided: Design, Installation, Project Management 
• Products Provided: Selective Rack, Cantilever Rack
• Locations: California and Ohio 

Concern: Large Range of SKUs to House in New Material Handling Systems

A hardware supplier was opening two new distribution centers: a 410,000 sq. ft. facility in Ohio and a 290,000 sq. ft. facility in California. The material handling systems for both distribution centers needed to accommodate the company’s 13,000 SKUs, which varied significantly in size, shape, and weight.  

The desired completion dates of the material handling system for each location were adjacent. Therefore, each project had to be coordinated simultaneously.   

Solution: Design Based on SKU Analysis

REB was chosen as the provider for both material handling systems. It was ideal for the company to work with one provider for both systems, and REB has the capabilities to project manage numerous material handling system builds at different points with the United States.  

REB thoroughly analyzed the company’s 13,000 SKUs, separating products into categories. Which category each SKU belonged to was based on several factors, including ideal position in the distribution center, size, shape, and weight. These categories helped designers develop storage solutions and locations that best fit each SKU group.  

Based on the analysis, REB designers developed layouts that include several selective rack configurations, customized to each SKU category. Additionally, cantilever rack was included as a solution for high selectivity and density of long items.  

Although the layouts differed for each location, because each location housed the same SKUs the storage solutions for each were the same. Read below for details on each of these solutions.

Solution: Custom Selective Rack Configurations

More than 2,700 bays of selective rack were included in the material handling system. Selective rack was chosen because of its versatility. Bay sizes within a selective rack system can be customized to suit ranges of SKU characteristics. Therefore, several configurations were included to optimize storage and handling of the company’s SKUs. The following are some of the unique storage solutions that REB implemented. 

To accommodate storage of long, thin, light items such as plastic sheets, REB designed tall bays with vertical rods of electrical conduit. The electrical conduit acts as a barrier to allow the sheets to be stored vertically. This method provides increased density compared to storing the sheets flat.  

The company also required storage of long, thin, heavy items such as sheet metal. Because of the increased weight of the sheet metal compared to the plastic sheets, it was determined that they had to be stored flat. To still provide high density storage of these items, REB incorporated rows23 bays with tight beam profiles of 6”. 

For tall or bulky items, M-dividers were installed within larger ground-level bays. The M-dividers prevent products from rubbing against one another.  

Solution: Cantilever Rack

Cantilever rack is made up of metal arms that project at a desired angle outward from uprights. Front beams are not included in cantilever rack. This open design makes cantilever rack ideal for storing and retrieving long items. Because the company has a range of these types of items, such as pipes, 74 cantilever facings were included in the design. 

Solution: Onsite Project Management 

Once the designs were finalized, a REB project manager was assigned to each location. Timelines were set for each location to ensure the on time implementation of each system. The REB project managers then hired all subcontractors, assisted in obtaining all permits, and oversaw the installation process.   

Because of the large and detailed scope of work, REB provided an onsite project manager for each location. The project manager was the onsite for the entirety of each project, acting as the go-to person for the customer and overseeing all subcontractors.

Outcome: High Density and Selectivity for Storage of Many SKUs 

REB designed a layout that enables this company to efficiently store and pick all 13,000 SKUs at each location. The design accounts for the variety of product shapes and sizes. By customizing the bays for the range of products, the material handling systems provide the company with the highest possible density and selectively within budgetary guidelines.   

The video below outlines the installation process for the Ohio-based distribution center. 

Are You Opening a New Distribution Center? 

At REB Storage Systems International, we look at each project as unique. While many have similarities for which we can leverage our experience and knowledge, each client has unique needs that must be met.  

We know expanding operations can be an overwhelming process. If you are expanding into a new distribution center, REB Storage Systems International can answer any questions you have regarding the design and implementation of a new material handling system or the installation process.   

To receive storage solutions that optimize your unique requirements, fill in the contact form or call (800) 252-5955.