Building a better warehouse instead of a bigger one

Sovena USA was able to address space issues within its operation without adding any more bricks or mortar.

08/31/2012


Jeff Leclau, warehouse manager, Sovena USAAs the country’s largest importer of olive oil, Rome, N.Y.-based Sovena USA has seen its business grow in recent years. The company was looking to expand its operation and had room to grow the physical space, but looked for another solution. Working with supplier Pengate Handling Systems, a Raymond Corp. supplier, Sovena was able to address this space issue without adding any more bricks or mortar. Key members of the team that put this project together talked about how to look at space in a new way.

Jeff Leclau, warehouse manager, Sovena USA: Even with an 180,000-sq-ft facility, we struggled to find a way to expand. Initially, it was challenging for our organization to determine whether to expand our facilities or to find a way to optimize our current space. While we had the capacity to expand, we were looking for the most advantageous way to accommodate additional importing and distribution needs.

In working with Pengate, we were able to optimize our current location by implementing a very narrow aisle (VNA) concept, tearing out all the existing racking and installing narrow aisle bench storage and pushback racking. We also were able to improve our material handling flow by segregating and storing like items or types together, which has allowed us to store more goods on-site and eliminate the needs for an offsite warehouse. As a result our lift truck travel time for picking and putting away orders has decreased, therefore increasing our efficiency.

Randy Belliboni, executive vice president, Pengate Handling Systems: When Sovena turned to Pengate for its restructuring needs, Pengate had the option of expanding the company’s current space or utilizing the existing warehouse more efficiently to accommodate its increased business needs. Over several months Pengate worked with Sovena to understand the product flow, lift truck velocity needs, and increased storage requirements in order to make the proper recommendation to either expand or maximize the existing building.

Narrow-aisle racking allowed Sovena USA to expand its existing warehouse capacity without expanding its physical space. Courtesy: Sovena USAThe new layout achieved the increased number of pallet positions needed to keep up with increased business levels. Pengate and Sovena were able to measure the ROI by monitoring the increased pallet moves, productivity, and storage capacity. The company also was able to project a return on its initial investment within 3.75 years.

Leclau: The decision to improve our current layout and operational plan was based on the input of two teams. Team A had to keep the footprint the same while doubling the space (pallet positions). Team B was given the task of designing a physical expansion that would accomplish doubling the space the same as Team A. In the end, Team A won out, especially because the bigger building would have resulted in an increase in costs, such as income taxes.

Pengate played a key role in helping us make this decision. Our goal was to be able to accommodate a growth rate of 10% to 15% over the next 4 to 5 years. In assisting our team in making this decision, Pengate conducted facility visits, guided various input sessions, and presented what it thought was the best solution for our business. From there, our team collaborated with Pengate to finalize the solution and moved forward with a reconstruction that would service about 15,000 positions.

It was Pengate’s unique understanding of our business, from finished goods and raw materials to the loading and unloading of our materials, that gave it the edge.



The Top Plant program honors outstanding manufacturing facilities in North America. View the 2015 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
A new approach to the Skills Gap; Community colleges may hold the key for manufacturing; 2017 Engineering Leaders Under 40
Doubling down on digital manufacturing; Data driving predictive maintenance; Electric motors and generators; Rewarding operational improvement
2017 Lubrication Guide; Software tools; Microgrids and energy strategies; Use robots effectively
The cloud, mobility, and remote operations; SCADA and contextual mobility; Custom UPS empowering a secure pipeline
Infrastructure for natural gas expansion; Artificial lift methods; Disruptive technology and fugitive gas emissions
Mobility as the means to offshore innovation; Preventing another Deepwater Horizon; ROVs as subsea robots; SCADA and the radio spectrum
Power system design for high-performance buildings; mitigating arc flash hazards
Research team developing Tesla coil designs; Implementing wireless process sensing
Commissioning electrical systems; Designing emergency and standby generator systems; Paralleling switchgear generator systems

Annual Salary Survey

Before the calendar turned, 2016 already had the makings of a pivotal year for manufacturing, and for the world.

There were the big events for the year, including the United States as Partner Country at Hannover Messe in April and the 2016 International Manufacturing Technology Show in Chicago in September. There's also the matter of the U.S. presidential elections in November, which promise to shape policy in manufacturing for years to come.

But the year started with global economic turmoil, as a slowdown in Chinese manufacturing triggered a worldwide stock hiccup that sent values plummeting. The continued plunge in world oil prices has resulted in a slowdown in exploration and, by extension, the manufacture of exploration equipment.

Read more: 2015 Salary Survey

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
The maintenance journey has been a long, slow trek for most manufacturers and has gone from preventive maintenance to predictive maintenance.
Featured articles highlight technologies that enable the Industrial Internet of Things, IIoT-related products and strategies to get data more easily to the user.
This digital report will explore several aspects of how IIoT will transform manufacturing in the coming years.
Maintenance Manager; California Oils Corp.
Associate, Electrical Engineering; Wood Harbinger
Control Systems Engineer; Robert Bosch Corp.
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
click me