Laminex National Rollout

THE CHALLENGE

Laminex recognised the need to upgrade their existing bulk stack storage solution to enhance both safety and operational efficiency across multiple sites.

While bulk stacking is effective for storing large, uniform items with minimal infrastructure, it was proving inefficient for Laminex. The block stacking method slowed operations due to its lack of selectivity. With different board colours stacked on top of each other, operators had to move and restack items to access boards of a specific colour. Given the size and weight of each board, only a limited number of packs could be moved at once.

Moreover, the frequent handling of boards increased the risk of accidentally pushing them into adjacent aisles, potentially causing damage to inventory and creating a significant safety hazard.

Laminex needed a dependable solution to prevent such incidents and protect both their workforce and stock.

THE SOLUTION – CANTILEVER SYSTEM IMPLEMENTATION

After observing the existing storage solution and operational flow, Safer Storage Systems (SSS) proposed an innovative solution that would not only address safety concerns but also enhance operational efficiency, selectivity, and flexibility.

SSS recommended a custom-designed cantilever racking solution tailored to accommodate Laminex’s five board dimensions, ranging from the smallest at 1200mm x 2400mm, to the largest at 1800mm x 3600mm.

To accommodate the larger board size (and all sizes below this), SSS locally engineered a cantilever solution with levels of 1800mm arms, as well as levels with 1200mm arms. Each level of the cantilever system is engineered to hold 2-tonne packs of board.

Additional support structure was also added at base level to ensure the boards remained level. This prevented bowing outside of allowable tolerance levels, which is particularly vital for the longer boards.

TRIAL SAMPLE SET

To ensure the solution precisely met Laminex’s needs, SSS developed a trial sample set at two sites, enabling real-world testing and adjustments before the full rollout. This meticulous planning and customisation guaranteed a solution that was perfectly aligned with Laminex’s requirements.

TRAFFIC MANAGEMENT & SAFETY ENHANCEMENTS

SSS also designed and implemented a pedestrian traffic management solution across key locations – installing over 500 metres of Armco safety barriers with handrails and 30 gates.

NATIONWIDE SITE ROLLOUT

Safer Storage Systems has commenced the roll out of this custom cantilever solution across multiple Laminex sites nationally. Each installation has been meticulously planned and executed, ensuring consistent quality and performance across all locations. This coordinated effort highlights Safer Storage Systems’ commitment to providing comprehensive, reliable solutions that meet the needs of businesses on a national scale.

THE BENEFITS

The tailored cantilever system provided Laminex with a more effective solution by offering:

• Enhanced Safety: The cantilever system prevents boards from being knocked into aisles, significantly reducing the risk of accidents and product damage.
• Greater Selectivity: The design allows for easy access to individual board packs, improving selectivity and minimising the time spent handling materials.
• Increased Flexibility: Capable of accommodating various board sizes, the system offers unmatched versatility in storing different types of boards without compromising on safety or efficiency.
• Operational Efficiency: The system streamlines operations, reducing handling time and increasing accuracy, enabling operators to work more efficiently.
• Better Space Utilisation: By increasing storage height from the previous maximum of 4 metres with block stacking to 6 metres with the cantilever system, Laminex were able to increase aisle space and selectivity.

CONCLUSION

Safer Storage Systems is dedicated to delivering tailored solutions that not only resolve immediate challenges but also provide long-term operational benefits and greater ROI. This project underscores the value of innovative thinking and customised design in enhancing safety, efficiency, and overall business outcomes for Laminex.