Removable shelves: the intralogistics revolution for Lean Production

• The concept of warehousing for Lean Production
• The virtuous company according to the Toyota Production System (TPS)
• The functional areas of a warehouse
• Storage systems
• Pull-out shelves for existing shelving systems
• The pull-out shelves at floor level
• Intralogistics and Lean Production

The concept of warehousing for Lean Production

In the Lean sense, the warehouse is not a static storage space, but a dynamic system that aims to maximise efficiency and reduce waste (such as overproduction, excessive stock and waiting times) to create value for the customer. It focuses on linear processes, low inventory and strategic product positioning to minimise movement and waiting times, thereby optimising the entire logistics flow.

From an operational point of view, there are two types of warehouses related to:

• production, which in turn requires a warehouse for raw materials and semi-finished products for production and a second warehouse for finished products;
• distribution, which requires only one warehouse where only finished products pass through.

For the purposes of this newsletter, we will limit ourselves to analysing the warehouse linked to production, with particular attention to the models for picking items and the way in which goods can be stored, both of which affect efficiency and therefore the competitiveness of the company.

The virtuous company according to the Toyota Production System (TPS)

According to the TPS A virtuous company is one that manages its business by eliminating inventory. However, the main objective is customer satisfaction, which every Lean company seeks to achieve by minimising the cost items involved in its activities:

• reception
• stocking
• picking
• packaging
• shipping

Storage systems

Areas dedicated to the storage and handling of materials can be organised with or without shelving, depending on the space available, the type of goods and the required handling flow.

The stacked warehouse“ (without shelving) is a storage system in which goods, often on pallets, are stacked directly on the floor. This method is advantageous for homogeneous, low-turnover products or as a temporary storage buffer for products awaiting sorting, storage or dispatch.

This type of warehouse does not require any investment in infrastructure and has a high surface yield, but it has limitations in terms of selectivity (it is difficult to access products that are not positioned at the front or in front of the aisle), height (the height of the stacks is limited by the strength of the product, its packaging and the type of flooring), as well as safety (if the goods are unstable, the risk of accidents increases).

I warehouses equipped with shelving, Although they require a significant initial investment, they offer several advantages over stacking warehouses. Shelving allows you to maximise the available space, concentrating large quantities of material in a limited area. In addition, these systems facilitate the monitoring of goods, from receipt to order preparation, allowing for quick product location. If the shelving is equipped with removable shelves, the advantages increase further.

Pull-out shelves for existing shelving systems

Key features

• Immediate integration with existing shelving
• Current system for smooth and silent extraction
• High load capacity from 200 kg up to 1500 kg per shelf
• Quick installation without structural modifications
• Full front access to stored materials
• Extraction from 70% to 100% or on both sides

Operational benefits

• 70% reduction in picking times
• Elimination of unnecessary staff movements
• Improvement of workplace ergonomics
• Immediate access to all items without movement
• Optimisation of existing space

The pull-out shelves at floor level

Technical specifications

• Floor installation for maximum stability
• High-precision telescopic system
• Load capacity from 800 kg up to 1500 kg
• Equipped with handles for easy removal

Strategic benefits

• Maximising storage density
• Reduction of dead space in warehouses
• Quick access to materials on both sides
• Flexible configuration for different types of products
• Long-lasting durability with minimal maintenance

Intralogistics and Lean Production

Intralogistics deals with the management of material and information flows within a warehouse, from the receipt of raw materials to the shipment of the finished product. Lean Production is widely applied in this context.

1. Elimination of waste (Muda)

• Reduction of unnecessary movements by operators
• Elimination of waiting times for material retrieval
• Optimisation of logistics routes

2. Flow improvement

• Immediate access to the necessary components
• Reduction of bottlenecks in processes
• Perfect synchronisation between storage and production

3. Just-in-Time (JIT)

• Facilitates timely replenishment of production lines
• Reduces intermediate stocks
• Improve material rotation

4. Process standardisation

• Consistent and repeatable picking procedures
• Reduction of operational errors
• Simplified staff training

The Value Stream Mapping (VSM) is a fundamental tool for visualising and optimising internal logistics flows. In intralogistics, this Lean methodology allows you to “photograph” the entire path of materials from receipt to shipment, accurately identifying hidden waste and inefficiencies.

VSM transforms intralogistics from a “cost centre” to a “generator of competitive value”.

How it works in practice

The intralogistics VSM maps every physical movement of materials: from goods receipt to storage points, from picking to production lines, right through to order preparation. Each step is timed and analysed to distinguish value-added activities from those that represent pure waste.

The immediate benefits

• Visibility
• Identification of bottlenecks
• Accurate quantification
• Design

Impact on results

Companies that implement intralogistics VSM see an average reduction of 30-40% in internal lead times and a 25% improvement in space utilisation. Mapping becomes the basis for strategic decisions on layout, technologies and processes.