If you need to maximise space in the warehouse, double deep racking may seem a good option, but how do you know if it could work in practice?  Warehouse simulation can help.

Double deep racking is where pallets are stored two rows deep instead of one, increasing the number of pallet locations and keeping product lines together. However, as only 50% of the products may be instantly accessible, will it be practical and efficient?

Before diving into double deep racking, it is important to understand the balance between storage density and pallet access. The Hyster® warehouse simulator can do this, giving a realistic representation of a warehouse with double deep racking. 3D images allow you to see what the operation will be like, providing a platform to try out double deep racking approaches and other strategies for warehouse operations.

Key data will include the normal arrival and dispatch patterns at the facility with estimations of the minimum, average and maximum number of pallets per load.

The Hyster® Warehouse Simulator accounts for the random nature of events and works on probabilities, giving a range of results closely simulating day to day operation variations.

Data on the size of the warehouse, racking dimensions, and the number of loading and unloading bays can all be altered to test different scenarios. The number and types of Hyster® materials handling equipment can then be modified.  For example, you may see that a Hyster® reach truck, featuring a moving mast for the double deep racking, might make a big difference.

Simulation for double deep racking

Each simulation also considers significant details of the warehouse operation.  For example, battery discharge, re-charging, changing times and rates. Operator shift patterns, break times and ability/permission to drive certain truck types will also be accounted for, as well as creep speed when forks are lifted, and even the degree of truck slow down when cornering, or when near another truck.

The simulation software can also simulate a variety of order picking methods and will show in clear graphical form where and when congestion occurs.

If you have new ideas for your operation and want to try them out before committing to a new fleet or reconfiguring your warehouse, the Hyster® Warehouse Simulator will provide a detailed operational forecast to help you make an informed decision.

Speak to your local Hyster® dealer to find out more.