Home' MHD Supply Chain Solutions : MHD Jan-Feb 2015 Contents "Ongoing collaboration between Breville,
Dematic and the developer helped ensure the
20,000 pallet location ColbyRACK storage system
provides the flexibility to meet Breville's needs, as
well as potential future customers who may have
different storage requirements," said Mr Brooks.
Packaging changes drive
need for storage system
For the past 20 years, Breville's distribution
operation was located in Botany, Sydney, across
two warehouses totalling around 23,000 m2.
"We were mainly block-stacking pallets
of goods, as the roof heights were too low to
warrant the installation of high-bay storage
systems," explained Breville's Stuart Roche.
"In line with our participation in the
Packaging Covenant, Breville has removed poly-
styrene packaging from many of our products.
"Accordingly, there was a resulting decrease
in overall package strength and integrity, and
we soon discovered that many products that
were previously suitable for block-stacking,
were now not.
"We could no longer rely on block-stacking,
and it was becoming increasingly apparent
that we needed to relocate to a new DC where
we could implement smart storage system
layouts and logistics procedures to achieve our
objectives in terms of capacity, performance,
productivity, flexibility and quality control,"
said Mr Roche.
"When we made the decision to relocate, we
evaluated a range of alternative storage system
types, including fully automated VNA systems.
Dematic carried out an extensive analysis of
the pros and cons of the different options, with
double-deep racks coming out on top for our
application," he said.
Opting for double-deep racks helped increase
the overall pallet storage capacity of the DC
by more than 30% compared to conventional
Racks go up before walls
to optimise layout
To make sure the storage system layout
optimised space within the new Minto DC's
four walls as efficiently as possible, Breville
designed the bare structural frame of the DC
first, so that Dematic could make the best use
of the actual floor space.
"Being able to install our racks within the
bare shell of the DC enabled us to really take
advantage of every centimetre at our disposal,
and optimise the layout and capacity of the DC's
storage systems," said Mr Brooks.
After Dematic had completed designing the
DC's various storage systems, the internal struc-
ture and roof were then able to be designed and
erected around the building framework.
Mr Roche explained: "This was one of the
best decisions we took during construction of
the DC, because this gave us the ability to cor-
rectly align skylights, sensors and lighting within
the aisles of the storage system, providing excel-
lent natural and assisted lighting throughout the
whole facility, significantly reducing the need for,
and costs associated with, conventional lighting.
We have also used step beams with wire mesh
decks in many areas, and these also allow light
to filter down through the storage systems."
The DC's very successful daylight-harvesting
program has seen it reduce lighting power
consumption by 17%, with resulting energy
Wider aisles pay for themselves
"Instead of trying to squeeze every last pallet
into the DC, we opted to create aisles about
300mm wider than normal to give our forklift
operators a bit of breathing space in which to
operate," said Mr Roche.
"This move has certainly paid off. In most
normal narrow-aisle forklift operations it is rare
for a forklift or reach truck operator to be able
to drive into the aisle and swing directly into
position for picking. The narrow width of the
aisle usually means they have to reverse a little
and then come forward into position," he said.
"I've been watching our forklift operators,
and I have yet to see one who has needed to
slow down, stop reverse, stop, and drive forward
again to make their turn within an aisle.
"The productivity benefits we have gained by
just making the aisles that little bit wider are fan-
tastic. It also makes our forklift drivers' jobs that
bit easier and more enjoyable, has dramatically
reduced product damage, and improves WH&S
on the warehouse floor," added Mr Roche.
Self-centring pallet guide rails are installed within the upper four levels
of the double deep racks to assist with safe pallet put-away and retrieval.
Left: Dock levellers improve
safety and comfort when
de-stuffing containers and
Right: By installing the roof
after the racking, Breville
was able to correctly align
skylights, sensors and lighting
within the aisles, providing
excellent natural lighting.
MHD SUPPLY CHAIN SOLUTIONS --- JANUARY / FEBRUARY 2015
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