A global medical equipment manufacturer improved throughput speeds and optimized storage by installing a 2-level Catwalk System using RiveTier Shelving. This Small Parts Storage solution consolidated inventory from pallet racks into high-density shelving, improving safety and accessibility while accommodating 20% future growth.
The Challenge: Managing Growth and Small Parts Inventory
A global manufacturer of medical equipment and patient care products was expanding a key division at one of its U.S. facilities. To support this growth, the company developed a second building for storage but needed a strategy to handle a projected 20% increase in inventory.
Key Issues:
- Inefficient Storage: The manufacturer was storing small surgical devices and products in large pallet racks, wasting space and creating retrieval inefficiencies.
- Throughput Speed: Moving small parts in and out of pallet racking was slow and labor-intensive.
- Safety Concerns: Using tall shelving without a catwalk system required ladders, introducing safety risks for employees accessing high-density storage.
The manufacturer weighed the options of vertical carousel storage versus a catwalk system and ultimately partnered with California-based Shelf Master to design a custom shelving solution.
The Solution: 2-Level RiveTier Catwalk System
Shelf Master recommended moving the small parts out of pallet racks and into a high-density RiveTier Catwalk System.
Optimized for Small Parts
- High-Density Shelving: The system utilized RiveTier boltless shelving configured with specific shelf levels to house small parts in 4-inch bins. This shift consolidated inventory that was previously spread out in inefficient pallet racking.
- Multilevel Access: A 2-level catwalk design allowed the manufacturer to double their picking output within the same footprint.
- Improved Safety: The catwalk system eliminated the need for tall ladders, allowing employees to pick products safely and quickly from both levels using carts.
Results: Doubled Output and Enhanced Safety
The RiveTier solution delivered immediate operational improvements.
| Outcome | Benefit to Client |
| Faster Throughput | The ability to pull product faster without ladders significantly increased throughput speeds. |
| Space Optimization | Consolidating small parts into appropriate shelving freed up pallet racks for larger items and maximized the building’s density. |
| Scalability | The system was designed to support the required 20% growth, providing a robust infrastructure for future expansion. |
| Operational Efficiency | The new layout reduced the time employees spent crawling up and down ladders, allowing for a smoother workflow. |
By transitioning to a Catwalk System with RiveTier Shelving, the medical supply manufacturer optimized its new facility, proving that the right mix of storage systems is critical for handling diverse inventory. Ready to work on your next project? Big or small, WPSS has experts ready to assist! We provide layout guidance, spec sheets, and recommend best-practice clearances to ensure an efficient and space saving design. Contact us today for a quote.