John Horsfall

Project Requirements

Overview

John Horsfall began trading over 160 years ago and has been providing high quality “in flight” textiles and linens to the aircraft industry across the globe for over 50 years.

Their success has meant that they were required to increase the capacity within it’s warehousing and distribution hub to maintain service levels and improve efficiency.

The Challenge

Warehouse Storage Limited were tasked to provide a solution for a compact system to store 240 no. pallets (1,600mm and 1,800mm high), comprising of various size boxes and some bulk pallets.

Due to the variety of stock, we decided to split the stock into bulk pallets and other pallets and boxes into two systems.

After various discussions and layouts regarding the options available, such as Pallet Live and a Shuttle System, our customer initially decided upon a simple and cost-effective drive in system to “house” the 240 pallets.

This comprised of a Drive-In block, 8 lanes wide x 10 pallets deep x 3 pallets high.

Together with a carton live gravity fed picking system for the smaller boxes.

Consultation and final design

John Horsfall then asked us to look at how they could further utilise unused space within the warehouse to increase capacity and help to future proof the business.

Working together we designed a pallet layout that allowed different height and weight pallets to be stored in specific locations that enabled all of the apex roof design to be utilised.

We also looked at their picking and order processes. We designed a carton gravity flow system that gave an effective box picking system in a compact area.

Boxed product to be loaded from the rear of the system and picked from the front utilising divider lanes. Bulk “replenishment” pallets were then stored over the carton flow to make restocking the system efficient.

Previously stock was picked from pallets on the floor which was inefficient and utilised a large floor area.

The new design has allowed 48 bulk pallets to be stored and 1,296no. boxes within 216 pick locations.

Installation/commissioning/Health and Safety

Once the final design had been agreed and signed of orders were placed,

Materials delivered and installation took place in two phases over a couple of weeks.

The installation was undertaken within strict Health and Safety guidelines and legislation.

All installers were appropriately certificated and worked to site specific risk assessments and method statements. Warehouse Storage Limited are CHAS CDM Accredited and our all of our managers hold appropriate H&S accreditations (Tech IOSH/SMSTS/SIERS)

Our contracts Director supervised the project working closely with John Horsfall to ensure it was completed on time and to budget.