No sick bays mean richer pickings
October 1st 2007

Webasto has improved storage density, increased picking efficiency and introduced better stock rotation by installing full-width roller track Span Track modules from The Live Storage Company to convert static pallet locations into dynamic live picking faces

We wanted to use the space in the warehouse more efficiently," says Robert Jarman, operations director at Webasto Roof Systems. "By introducing the Span Track modules we have improved picking efficiency and probably tripled the storage density in the areas we have reconfigured." Webasto produces an extensive range of standard products and must stock a large number of components to maintain production. It also supplies spares for older products and the ability to pick efficiently is important to overall customer service. The company was storing items in conventional pallet racking but recognised that this was an inefficient use of the available space which did not support good stock rotation or productive picking. Items were picked and replenished from the same side of the racking which meant that components at the front would always be selected before those behind. Space had to be left on the front of the pallet for replenishing stock which meant that the density of items at the picking point was always low. Finally, staff had to lean or stretch to reach items at the back of the pallet or shelf which was inefficient, inconvenient and unproductive.

"Storing items on pallets does not lend itself to quick picking or using the oldest items first," says Robert Jarman. "Our plan was to get rid of pallets and pick from the front face so that we could improve stock rotation and density." After assessing a number of options and potential suppliers, Webasto selected The Live Storage Company's modular Span Track live roller track system. The Live Storage Company supplied the Span Track units in predetermined lengths and widths matched to the dimensions of the existing racking and the boxed items being stored. Webasto reconfigured four pallet locations with Span Track units on four levels to create 40 live picking tracks. This was achieved by repositioning the existing cross beams and adding new ones to support the Span Track units. Vertical spacing was matched to the height of the boxes so that the maximum number of picking points could be installed in the existing face. The Span Track units were then simply dropped into position, supported by the beams, to create a picking face with the maximum possible density.

The new picking zone accommodates lightweight boxed plastics and metal components used in Webasto's manufacturing process. Items are replenished at the rear of the racking and fed by gravity down the shallow rollered incline of the Span Track module to the front face at the optimum position for picking so that staff do not need to stretch to reach them. Because the width of each Span Track unit is matched to the dimensions of the boxes items are presented singly and in sequence to the pickers. This ensures that Webasto can maintain first in-first out picking stock rotation

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