5 tips to work up, not out!  Unlock your existing fulfillment facility’s potential by making every cubic inch work for you.

Maximizing efficiency within your existing facility is key to staying competitive in today’s fast-paced fulfillment landscape. With the right strategies, you can elevate your operations without a full-scale overhaul or hefty capital investments. Here’s a look at a few impactful methods to boost productivity and make the most of your current setup.

 

5 Tips to Maximize Efficiency in Your Existing Facility

  1. Optimize Every Cubic Inch
  2. Scale Your Operations to Match Demand
  3. Integrate Adaptive Technology Using Existing Assets
  4. Focus on Rapid Time-to-Value
  5. Transform My Existing Facility: How do I start?

 

 

1. Optimize Every Cubic Inch

In the current warehouse market, it’s not just about square footage – every cubic inch counts. Tapping into the full height of your space can uncover hidden value and drive greater efficiency.

To get the most out of your current facility’s footprint, rethink your use of vertical space. By maximizing upward storage, you can significantly boost inventory density without expanding outward. Many facilities miss the opportunity to leverage vertical space effectively, but by doing so, you can potentially double or even triple storage capacity within the same square footage.

Work Up – Not Out with ASRS

Consider implementing vertical storage solutions, like Automated Storage and Retrieval Systems (ASRS), which not only improve space efficiency but can also streamline picking processes. Studies show that efficient vertical utilization can improve storage density by as much as 40-50%.  With height capabilities up to 39+ feet, your storage footprint is condensed by up to 75% – giving you more room for inventory and reducing the need for costly expansions​.

Maximum Boost with ACRs

Automated Case Retrieval (ACR) systems are a game-changer when it comes to maximizing the storage potential of your facility. By efficiently utilizing vertical space, ACR technology can increase storage density by up to 80%, allowing for far more inventory within the same footprint. This vertical integration not only reduces the need for additional warehouse space but also enhances operational flow by optimizing pick times and minimizing worker travel distance.

With ACR systems, you can make every cubic inch of your existing facility work harder, achieving impressive efficiency gains without needing extra space. Companies using ACRs are seeing remarkable results: up to 67% in reduced labor costs, a 4X boost in operational efficiency, and a 3X increase in order throughput – all with an order picking accuracy of 99.99%. It’s a powerful advantage for any facility ready to do more with what they’ve got.

 

2. Scale Operations to Match Demand

When facing or anticipating shifts in demand, you’re likely considering options like consolidating, relocating, or expanding your distribution network to stay agile and efficient.

When facing or anticipating shifts in demand, you might be weighing options like consolidating, relocating, or expanding your distribution network to stay agile and efficient. But scaling to meet demand doesn’t always require major changes in location or layout. With today’s flexible ASRS solutions, you can boost capacity right within your existing facility.

ASRS enables precise, high-density storage, maximizing vertical space so you can store more without expanding your footprint. During peak periods, it seamlessly adjusts inventory flow and fulfillment rates, ensuring your facility keeps pace with demand. Adopting this strategy ensures you’re prepared for growth without the added costs or disruptions of relocation or expansion.

Modularity Empowers Incremental Scalability

With a more adaptable approach than traditional grid-based ASRS, flexible systems empower you to scale incrementally. You can add ports, workstations, totes, cases, robotic systems, and storage racks seamlessly, allowing steady growth without interrupting daily operations. This modular approach supports long-term scalability, allowing your facility to evolve smoothly alongside demand.

Integrating modular automation with your existing assets can give a substantial boost to cash flow. With reduced labor expenses, maximized storage efficiency, and less need for costly expansions, these systems help maintain tight control over operating costs. Incremental automation implementation lets you ramp up capacity as needed, aligning with demand shifts without requiring large initial investments – enabling strategic growth and steady cash flow management.

 

3. Integrate Adaptive Technology Using Existing Assets

By using your existing totes, containers, racks, and WES/WMS technology, automated solutions can significantly enhance operational efficiency without the need for extensive changes.

To drive efficiency and adapt quickly, leveraging flexible, adaptive technology is essential. Automated solutions can seamlessly work with your existing assets, significantly boosting operational efficiency without the need for extensive changes. With adaptable automation, facilities can scale incrementally, avoiding major disruptions.

Advanced robotics and automated systems can be integrated modularly into your existing system, often with plug-and-play connectivity, allowing for upgrades or adjustments that suit your current operational demands. This level of flexibility not only improves productivity but also future-proofs operations against evolving market conditions.

Reduce Cost by Implementing Changes in Stages

Flexible automation systems are particularly beneficial because they allow facilities to implement changes in stages. This modular approach enables the gradual addition of storage units, picking stations, or transport robots as demand requires, preventing the need for extensive restructuring or downtime.

As a result, facilities can operate with a higher level of responsiveness, accommodating shifts in demand while keeping costs manageable.

 

4. Focus on Time-to-Value

Focusing on time-to-value means opting for solutions that hit the ground running, delivering immediate results and seamless integration.

What is Time-to-Value?

In simple terms, “time-to-value” is about how fast you start seeing real benefits from your investment. Instead of waiting months for a new system to pay off, focusing on time-to-value means choosing solutions that quickly integrate and make an immediate impact.

It’s like getting a quick win – you’re able to boost efficiency, cut costs, or improve productivity right away. This approach helps you keep things running smoothly while maximizing the return on every dollar spent, making sure your facility is ready to meet demands without missing a beat.

Keeping Your Time-to-Value Short

Prioritizing time-to-value in your fulfillment operations allows you to see a quicker ROI. By implementing modular, scalable technologies that integrate seamlessly, facilities can start reaping efficiency gains with minimal delay.

This approach reduces the disruption typically associated with traditional system upgrades and enables facilities to optimize their workflows swiftly.

Identify Risk to Keep Your ROI on Track

Selecting an experienced automation integrator is key to keeping your time-to-value short and your ROI on track. A skilled integrator understands how to seamlessly incorporate new systems into your existing operations with minimal disruption, reducing the risk of costly delays or inefficiencies.

With their expertise, you’ll start seeing real benefits fast – gaining efficiency without the usual delays or budget overruns. The right integrator helps you avoid common pitfalls, ensuring a quicker, more reliable return on your investment and setting your facility up for long-term success.

 

5. Transform My Existing Facility: How do I start?

Ready to unlock the full potential of your current fulfillment facility? Discover how smart automation solutions can enhance efficiency, streamline operations, and scale with demand – all without costly overhauls. Learn practical strategies to drive fast ROI and see immediate benefits.

Connect with IndPro today – and let’s make your automation goals a reality.

 

 

About IndPro

IndPro Services, a leader in Commercial Systems and U.S. Federal Government procurement, designs and executes successful, data-driven automation and robotic solutions for supply chain industries.

Dedicated to improving efficiency in warehouse and distribution center operations, we work on the same side of the table with you to procure the best possible solution, tailored to your budget and needs.