When a Melbourne based auto parts distributor approached Erect-A-Rack, their warehouse was bursting at the seams. The team was struggling with limited floor space, mismatched shelving, and inefficiencies in their picking process that were starting to affect fulfilment times. They needed a smarter solution not just more racking.
Here’s how Erect-A-Rack helped them transform their storage setup, boost productivity, and prepare for growth.
The Challenge
The client’s operation had grown rapidly over a few years, but their warehouse hadn’t kept up. They had a mix of outdated racking, makeshift shelving, and stock that was being stored wherever there was room. Staff were losing time navigating a cluttered floor and regularly handling stock multiple times due to poor layout.
They needed to:
- Maximise vertical space
- Create logical pick zones for fast-moving SKUs
- Improve forklift access and safety
- Future-proof the space for expanding product lines
Our Solution
Our team began with a full site audit, taking measurements and observing how the warehouse operated on a day-to-day basis. From there, we developed a tailored racking solution using a mix of pallet racking, long span shelving, and a mezzanine floor.
We reconfigured the layout to streamline pick paths, opened up wider aisles for forklift access, and used taller racking to fully utilise the vertical height. By zoning the space according to SKU velocity, we placed high-turnover stock in easily accessible areas, while bulk storage moved to higher racks.
Key elements of the solution included:
- Selective pallet racking for mixed-sized inventory
- Long span shelving for hand-picked items and parts
- A mezzanine floor that added 40% more usable space without expanding the footprint
The Results
The impact was immediate. Fulfilment times dropped, errors were reduced, and staff could move more efficiently through the space. The new layout improved safety by separating pedestrian and forklift zones and eliminated the clutter that had previously slowed everything down.
Highlights:
- 40% increase in usable storage space
- 25% reduction in picking time
- Improved stock visibility and access
- A layout built to scale as product lines grow
Final Thoughts
For businesses like auto parts suppliers where product diversity, fast picking, and inventory accuracy matter custom racking solutions make a real difference. By partnering with Erect-A-Rack, this client didn’t just solve their immediate storage problem, they positioned themselves for continued growth.
Need a smarter warehouse setup? Contact us for a tailored solution that’s built to fit your business.
