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Warehouse Genius FAQs

Is there a table with average honey comb values for the different combinations of warehousing segments (grocery, construction materials, appliances, and so on) with different racking systems (selective racking, double deep racking, drive in, and drive through)? A set of guidelines with approximate values would be helpful.

What type of racking do we need?
Please see this calculator: Pareto Calculator

Based the number of SKUs and total number of pallets, using the following guide may be useful on honeycombing per each type of racking used:

Selective rack – Storage unit of measure is one.  Honeycombing is not a problem with selective rack, as the system never puts one pallet in front of another.
Double deep rack – Storage unit of measure is two.  Honeycombing is a function of average # of pallets per SKU relative to the number of pallet slots in a location.  If the average pallet quantity is 3, honey combing in double deep would either be quite high, maybe 25%, or there would be a need to put a different SKU in the front position, requiring the occasional double handling.
Pushback rack – Storage unit of measure usually 3 to 5 deep.  Works well with quantities in the 10 to 20 pallets per SKU range.  As an example:  5 deep pushback and a particular SKU has 12 pallets, two lanes are full and one lane has 2 pallets.  3 out of 15 spaces are empty, giving 20% honeycombing.
Drive-in Racking – Storage unit varies a great deal, but 5 deep x 4 high is common, as the 20 pallet positions approximate a truck load.  If average pallet count per SKU is 70, 3 lanes of 20 would be 100% and one lane with 10 pallets is 50% empty.  Overall 10 / 70 honeycombing is 14%.  If the average SKU count was 25 pallets with the same drive-in system, typical storage might be 20 pallets in on location and 5 in another, with 37% honeycombing.
For effective use of space, most warehouses will be better served by a mix of pallet storage systems such as 5 deep pushback and some selective rack.  This allows  a 5 deep pushback lane to be available for 5 pallets by moving  quantities of 1 to 3 pallets to the selective rack.
It really does not matter what industry it is, the key is to understand the inventory mix and design rack from there.  Also, most the above systems need the pallet size to be consistent.  Selective rack with decking is the best solution for a wide range of pallet sizes.   

Also, please be sure to read our write up on: Pallet rack types for the warehouse


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