Mezzanine Floors, Pallet Racking systems, Office Partitions - Installers & Suppliers UK

Services:

Solutions:

Case Studes:
Consultancy and Design

Project 1:
DISTRIBUTION WAREHOUSE - SCOTLAND

In February 2002, MEZZ-RACK SYTEMS was invited to the office of a leading Building Contractor based in Edinburgh. We were provided with very little information other than an existing customer of ours had highly recommended our warehouse design service.

On our arrival it was explained to our Senior Consultant that their client for whom they had just built a large manufacturing facility was intending to move their warehousing to the same site.

Requirements

Our brief was to submit a design layout for a workable Pallet Racking System. Unfortunately, the Building Contractor had no information about a) The product box sizes - pallet sizes or b) Size of warehouse - only that it could be no higher than 14.0 metres. We were told, however, that the client was working from two existing warehouses in the North of Scotland and North West of England.

It was agreed that our work load for this would be excessive and a Consultation and Design Fee was agreed. However, it now transpired that we only had a period of two weeks to collate and assess all the information, design a system and produce our findings for presentation to the end user.

Two Consultants were used and visited both existing warehouses on the same day whilst our Senior Consultant visited the Logistics Manager, Financial Director and Operations Manager of the Manufacturing Plant. From this meeting it was evident that the Company had never gone down the route of main distribution and their comments were vague, to say the least, but between us we did manage to compile the necessary data to come up with at least an idea for them. This basic information being:

1. Number of manufactured goods ready boxed for 24 hour delivery.
2. Number of manufactured goods - fast moving stock.
3. Number of manufactured goods - slow moving stock.

It was noted from our visits to the other warehouses that pallets of all shapes and sizes were being used. We had to ignore this and standardize throughout. By using a pallet of 1200mm deep by 800mm wide we could accommodate every box size comfortably.

We now had to design the racking layout for a warehouse that did not exist and our brief from the end user was to, quite simply, design whatever you think best. We now knew that we had to accommodate for at least 12,000 pallets and that by utilizing the full 14.0metre suggested height we could store these pallets in a less restricted area. Due to the type of product and its casing being flammable we also had to take into account that sprinkler systems would need installing within the racking system.

With all this information now finalized it was now quite straight-forward designing a system to suite. A warehouse facility of 86,000 sq. ft. was more than suitable and a designed racking layout consisting of:

• 12 double entry runs of 26 bays (split halfway for truck maneuverability).
• 2 double entry runs of 26 bays ( full length ).
• Each rack 12.5m high accommodating 5 beam levels ( 6 pallets in height )
• 11,700 pallets would be stored in these racks.

Racking, serviced by 6 V.N.A. Order Pickers, and 3 number V.N.A. Combis with a sprinkler system at every other level, including roof height. Fast moving items remained on the lower four levels with the slow moving items stored on the top beam.

All manufactured goods issued for immediate delivery was stored in a specially designed First In First Out (F.I.F.O.) live storage system located close to the loading bays. This system would accommodate 400 pallets.

The racking system and battery charging area would take up 78,000 sq. ft of the Warehouse leaving a redundant space of 8,000 sq. ft. When asked by the client the best way to utilize this space we suggested a mezzanine floor for office accommodation down stairs and canteen facility and rest room upstairs. The portocabins that were currently being used outside for this purpose could be taken away and the space left could be used for extra parking facilities.

Outcome

Our designs and ideas were accepted by the Contract Manager and the End User and the warehouse is now up and running. Our client informed our Consultants that although our fee structure initially seemed excessive he believed that our negotiations with the suppliers and installation contractors and our first rate project management and control of these personnel had saved his company a figure in the region of £70,000.

Our Consultancy and design is totally unbiased and we will not offer our own product
as a result of an accepted design unless asked to do so.

Project 2:
ELECTRICAL COMPONENTS (CENTRAL WAREHOUSE)
- NORTH WEST

In December 2001, MEZZ-RACK SYSTEMS was awarded the contract to design and implement the layout of a storage system and complimentary handling equipment for our client's new central warehouse. Our proposal package was extensive and, although we were not the most competitive, we offered a great deal more than the other bidders.

We believe that our totally unbiasedapproach clinched the Order, as the client made it clear to us that his dealings with a number of manufacturers and suppliers had only confused his ideas of what was actually needed. Indeed, on scrutiny of our competitors proposals, it was evident that each of them was offering a design package that would suit only the supply of their own materials.

Requirements

An existing warehouse of 65,000 sq. ft. had been located and it was up to our consultants to design systems working to the following parameters;

• Design fully operable working systems.
• Advise on material handling equipment.
• Design office and canteen facilities for warehouse work force.
• Discuss warehouse sprinkler design.
• Discuss lighting and heating requirements.
• Implement systems.
• Set out tenders and procure materials.
• Contract/project manage the installation of the systems.
• Hand over and commission systems and handling equipment.

We were set a very stiff target to have the warehouse fully operational within nine weeks, however our client was very helpful with the information that was required to design a racking system and, with their assistance, we managed to design a system for their palletised goods very quickly. It was extremely important that this was implemented as they were in the process of clearing out their two other depots in the Midlands and Lincolnshire, resulting in 5,000 pallets of stock stored temporarily in an adjacent warehouse, at cost, for a nine week period.

The design of the Pallet Racking System was simple and by discussing a number of options of material handling equipment with our client we quickly came to an agreement on the final design. This decision was crucial because of the manufacturing time scale of the Truck manufacturers.

A racking system for 8,500 pallets was approved using 5 no. VNA wire guidance man up trucks lifting to a height of 12.2 metres. We did, however, still have to store over 170,000 boxed items of varying size and by now the warehouse capacity was dramatically reduced. A 9,000 sq. ft. area was still available in which we had to accommodate a carton live storage and longspan shelving system with a storage area covering 16,000 sq. ft., not forgetting the office and canteen facilities for the 16 no. warehouse work force. We requested a visit from the Local Authority Building Regulations and after a brief discussion they offered initial approval for a 9,000 sq. ft. 2 tier mezzanine floor allowing a total area of 27,000 sq.ft. - this floor, incorporating carton live storage on the ground level, large boxed items on Long Span Shelving in the first floor, allowing office and canteen facilities on the upper floor.

The overall design of the systems was straightforward once all the relevant information had been collated. We now had to re-design the in-rack and warehousing lighting, also incorporating that of the undersides of the mezzanine floors and office environment.

A total of 30 tenders was prepared and issued to suppliers and contractors, allowing only 4 days for return. The response was excellent and Orders were placed the same day. The only problem we had was choosing the supplier of the sprinkler system, not because of cost but it was essential that the water tank was installed and operable within the now eight week time scale.

The installation of all the systems was managed by one of our contract managers who organized deliveries and installation schedules so that contractors would not be in each others way.

Outcome

The overall cost of procurement of all systems and contractors was £973,000, including our fee of £29,500. The client informed us that their budget of £1.2 million was based on the accumulation of budgetary prices from suppliers at the initial concept.

MEZZ-RACK SYSTEMS saved their client an estimated £227,000. As a thank you they offered a £8,000 bonus which we refused. However, we have accepted an Order from their sister company to undertake a similar project.