PEK3 flow racks –
Logistics and warehousing play a crucial role in all production companies. When logistics is poorly organised, the effects are felt throughout the business – from production to customer deliveries. Individually adaptable flow racks from PEK3 are highly efficient storage systems that help you optimise your logistics and warehousing in a variety of ways.
- Modular system
- Optimal “Kaizen” tool
- Easier stock keeping
Flow rack: definition and functionality
A flow rack is a system in which goods are loaded on one end and transported to the other end, where they are removed. Transportation of the goods through the rack is purely mechanical through the force of gravity. The side where goods are loaded is slightly elevated, creating a slope down to the removal point. Free-moving rollers are mounted on the shelves. The containers (small load carriers) therefore move to the end of the rack on their own. Here they are held by a stopper.
Flow rack: Advantages and disadvantages
Flow racks offer numerous benefits for logistics.
First in – first out (FIFO principle)
The racking system is designed so the goods that are put in first also reach the next station first. This means that further processing always continues with the oldest products first. Such a system is particularly useful for operations that, for example, process perishable goods.
Mechanical mode of operation
Containers are transported through the rack by gravity and no electricity is consumed. That saves energy costs and the racking system can also be used during a power failure or at sites with no electricity supply.
Modular design
Our flow racking system is made of modular elements and can be perfectly adapted to meet the individual needs of your business.
Optimal utilisation of available space
Storage space costs money. With a flow rack, you can realise the full potential of your storage space. Pallets loaded with goods are loaded at one end, move through the rack on their own and are only removed again at the other end. Aisles between the racking rows for pickers, equipment and vehicles are therefore eliminated. Compared to conventional racking, a flow rack therefore gives you up to 60% more storage space. Optimal utilisation of the available space lowers the storage costs for your goods.
Efficiency
Flow racks offer a practical option for efficiently connecting two consecutive stations. This connection does not have to be one-sided. With multiple racking levels, you can also implement processes where goods and materials move back and forth between various stations.
Costs
The comparatively low procurement costs are quickly amortised because a well-planned warehouse racking system tremendously reduces the total picking time in day-to-day operations. What’s more, the Easytube pipe racking system has a long technical service life and requires very little maintenance. If a pipe, connector or roller track does have to be replaced because of wear or damage, the cost is very low thanks to the modular design.
Modular and efficient
Warehousing and logistics are important company departments. Among other things, they are crucial for efficient production and deliveries to customers. A pallet flow rack can effectively support this efficiency. This is possible thanks to its modular design, permitting you to customise and tailor the system to your needs.
We provide key information about the pallet flow rack in this summary overview. Friendly advice at no charge is provided if you have any questions.
A love for products since many years. We develop solutions for assembly and production.
We meet your requirements. For all your needs. We offer a solution tailored to you.
We never stop. We are always developing new innovations. See for yourself.
Difference compared to conventional racking
Warehousing and logistics are important company departments. Among other things, they are crucial for efficient production and deliveries to customers. A flow rack can effectively support this efficiency. This is possible thanks to its modular design, permitting you to customise and tailor the system to your needs. We provide key information about the flow rack in this summary overview. Friendly advice at no charge is provided if you have any questions. You can of course store components and products using conventional racking. However, the flexibility is very limited as a rule. With the Easytube flow rack, the name is the game: small load carriers, various containers and goods can be easily transported thanks to the racking system’s integrated height difference. The sophisticated movement of goods is possible without electricity – using only the force of gravity. Roller tracks that can be individually positioned form the basis for this movement.
Modular design
No two companies are the same. Therefore, the requirements profile for optimal logistics is going to be different as well. Especially in companies with extensive stock-keeping, a custom racking system that precisely meets the specific operational needs is indispensable for economy and effectiveness. The modular design of the flow racking system makes it an excellent choice for this application – both in terms of organisation and from a cost perspective. A pallet flow that follows your operating processes without detours can be realised with a comprehensive range of components that are individually configured by you.
A convincing benefit: First in - first out
The inclined roller track in the flow rack is an example that demonstrates the key benefits of this racking type. New goods or containers are always loaded into the rack in the highest point. The other containers move down, making the implementation of the first in, first out warehousing system child’s play. The container removed by workers at the front of the racking system is the one that was loaded first. Thanks to its features, the flow rack also provides truly effective support for your business as a buffer store for shipping and production.
Cost-effective work processes with the pallet flow rack
First in – first out operation with the roller system also convincingly demonstrates the cost-effectiveness of flow racking. For one thing, the movement of goods is realised mechanically through the height difference, saving on electricity costs. For another, the defect rate at the time of removal is reduced since products subject to deterioration (corrosion risk, for example) are discharged at the bottom. The labour expended by your team is reduced as well since the containers are transported and made available by the system with a high degree of automation. Productivity in your business is also supported by the organisational separation of supplying and removing goods.
Positive impact on the storage volume
Your company’s warehousing capacity is an important factor for production as well as customer satisfaction – and thus, a significant competitive advantage? The flow rack is a useful option here as well. Compared to conventional racking, the space available for the storage of goods or containers can be increased by up to 60 per cent. Two painful bottlenecks for your business are efficiently avoided this way – production stoppages with all associated costs, and late deliveries that can have a negative impact on customer retention. Implementing the first in, first out principle in the flow of goods also minimises reject costs for your business, providing an economic benefit.
Kanban racking system –
highly efficient, systematic supply
Logistics without kanban systems would be unthinkable today. They are especially beneficial in complex production processes and when the available storage space is very limited. Once the organisational structures have been established, the system is highly efficient for utilising available capacities and minimising transport distances. Kanban systems are self-regulating and flexible with decentralised control. Combined with the PEK3 modular pipe racking system, you can optimise the space available for logistics and free up additional resources.
A love for products since many years. We develop solutions for assembly and production.
We meet your requirements. For all your needs. We offer a solution tailored to you.
We never stop. We are always developing new innovations. See for yourself.
History of the kanban system
“Kanban” is a word of Japanese origin that roughly translates as “visual card”. Data cards play a central role in case of the racking system. They are used to control individual processes in logistics and production. Initiated in the 1950s by the former manager Taichi Ohno, Kanban was used in Toyota’s production facilities. But the original idea behind it goes back even farther. At the outset, it was used primarily in supermarkets and the food industry. Racking forms the core of the Kanban system. A card is assigned to each item in the system. In addition to the designation and article number, it contains information about the storage location, remaining quantity and more.
Advantages of the kanban system
The kanban system combines several tangible benefits for logistics. It supports decentralised control, just-in-time (JIT) logistics and highly efficient use of storage space. This is a big advantage, especially when storage capacities are limited, since the use of the available space is optimised. Empty, unused areas are eliminated along with the accumulation of excess items that are rarely used. All required parts are continuously available or quickly replenished and the time expended to search for an article is minimised. Unnecessary transport distances are also eliminated, freeing up additional capacities.
Requirements
The kanban racking system is not always sensible or even usable in all cases. For example, an important perquisite for using it efficiently is that the respective material consumption is as predictable as possible. The kanban system can compensate for minor deviations relatively well. But if larger fluctuations happen frequently, that is a problem for employees in logistics. Consistent, well organised assignment of all racks and the individual containers also decisive. All employees must strictly adhere to the storage locations that are precisely defined in advance. Otherwise, mistakes due to incorrect assignment happen and require considerable time to correct. This interrupts or slows down the entire production chain in the worst case.
The appropriate racking system
The first thing you need to use the Kanban system is suitable racking. It has to ensure that all goods can be exchanged quickly and easily. Time is always a crucial factor in logistics. To save time and prevent employees from hindering each other, Kanban racking systems are generally accessible from both sides. Naturally, there needs to be sufficient space for the required goods, which have to be flexibly stored in the smallest possible space. After all, unused storage space is a squandered resource or Muda – the Kaizen term for waste. Standardised heavy-duty racking arranged in parallel is often used in large warehouses. However, more flexible alternatives that can only be realised with modular systems are needed in many cases.
We advise and support you
If you are thinking about better, more cost-effective solutions for ergonomic workstation design in assembly or production, you should talk to us. The experts at PEK3 are happy to advise you in detail regarding the features, possibilities and advantages of the proven Easytube pipe racking system and other aspects of ergonomics.
Stainless-steel pipes
Kanban racking systems made of stainless steel pipes are made for demanding applications. They are used, for example, where aggressive chemicals could attack, deform and damage plastics. They are also ideal for clean rooms and applications where a premium look is desirable. The high conductance of stainless steel pipes is a major benefit in production facilities for electronic components.
Powder-coated tubes
This is a very economical alternative. A special coating is applied to the surface of the individual elements, making the pipes scratch-resistant and protecting them against the effects of chemicals. Effective corrosion protection is additionally applied to the inside for long-term durability. You can choose from many different colours to further improve the organisation of your kanban racking systems.
Plastic-coated tubes
Kanban racking made of plastic-coated pipes is most commonly used in logistics. The core of robust, high-grade structural steel is surface-coated in production before a special adhesive is applied. This holds the final ABS coating in place. Corrosion protection is applied to the inside of the pipes to permanently prevent rust. As with powder coating, the ABS coating is available in multiple colours. Different warehouse sections can be visually distinguished in this way, creating a clear structure and improving organisation.
PEK3 is your partner of choice for flow racks and much more
A flow rack has many advantages and can be used for numerous applications. Thanks to the modular design, you can tailor the system precisely to your requirements and optimise processes according to your needs. Are you debating whether a flow rack is the right choice for your business? We are happy to help you optimise your logistics and assist you with finding the right solution for your needs. Our expert advice is non-binding and free of charge for you. Get in touch with us by phone, e-mail or our contact form. We look forward to supporting your next project with insightful consulting and many years of experience.