Where you are : Home » Case Studies » Chubb
Increase / Maximise Warehouse Space & Reduce Storage Costs for Chubb
The Scope
Chubb, famous for its fire protection and security products, was faced with two dilemmas at its Hams Hall warehouse and distribution facility, Firstly how to increase capacity to take account of new product lines and reduce outside storage costs and how to create an additional 6000 ft² to house a new "in-house" dry powder recycling operation.
Due to operational constraints, 50% of the warehouse had to remain fully operational at all times in order to ensure that customer orders could be fulfilled and delivered on time.
The Solution and Work Completed
The existing 1990’s low rise pallet racking with 500 no base picking locations, which served as a pedestrian order picking facility during the day, was dismantled on a "row by row" basis working from 9.00p.m until 5.00 a.m. the next day five nights per week.
The racking was re-built using a heavy duty base extension frames. This new configuration provided a further two beam levels in the height.
Each day at 6.00 a.m. the entire area was cleared of installers, plant, materials and handed over as "'fully operational" to the morning shift.
Not only was the rack height extended and a further three beam levels introduced in bay 2, but the operating aisles reduced from circa 3000 mm to 1800 mm to accept a wire-guided "man up" narrow aisle truck.
Again this work was carried out on an "aisle by aisle" basis, working from 9.00 p.m. to 5.00 a.m. the next day over a period of days/weeks.
By working through the night, disruption to operations was minimal and safety was not compromised.
This contract was carried out over a 12 week period and it was handed over on time and within budget.
Bay 2, which contained generally raw materials in bulk format, was able to be converted into a high-rise narrow aisle operation, releasing much needed space for the new recycling operation.
Project Summary and Key Points
- Existing warehouse size 81,500 ft²
- Original pallet capacity 5,400
- Extra over increase 2,200 pallets (+ 41%)
- New recycling area created 6,000 ft²
- Existing racking increased in height from 8,700 mm to 10,500 mm by using heavy duty base extensions.
- Pallet levels increased from 5 to 7 levels at the eaves and 8 in the apex of both bays
- Reach trucks upgraded for use in Bay 1
- Wire guidance and man-up narrow trucks introduced in Bay 2#
