When a warehouse runs smoothly, it becomes a well-orchestrated system where every process, from warehouse inventory control to employee safety, works in perfect harmony. This harmony is what makes warehouses sexy, according to Kevin Lawton, warehouse expert, creator, and host of the New Warehouse Podcast.
In episode 17 of Secret Life of Inventory, we sat down with Kevin to tackle the critical aspects of warehouse management that can make or break your operation. Checkout the full episode below or read on for a quick recap.
Standardization: the secret to seamless warehouse operations
One of the most practical takeaways from our conversation with Kevin is the importance of standardization. It sounds simple, but the impact is profound. Kevin illustrates his point with a mundane everyday task. Sweeping. Without standardization, a worker who uses a broom will just leave it anywhere. Then, when the next person needs the broom, they’ll have to hunt it down, wasting valuable time.
The solution? Have a designated home for the broom. This highlights the fundamental principle of standardization. Eliminating decision-making from routine tasks.
The goal is to create processes so standardized that workers don’t need to think about basic operational decisions. This will reduce errors, improve efficiency, and create consistency across shifts and teams.
Why warehouse inventory control deserves more love
Inventory control is often the most undervalued department in warehouse operations. Kevin puts it perfectly when he says you need to “give lots of love to your inventory control team.” Why? Whether you like it or not, inventory accuracy is the backbone of your entire business operation.
For example, when your system shows two pieces available but there’s only one on the shelf, you’ve just created a ripple effect that impacts pickers, slows down operations, and potentially costs you a sale. It may not seem like a big deal, but the time spent searching for that missing item, the labor costs involved, and the potential lost revenue all add up quickly.
The key is preventing these mistakes before they happen. This means you need to understand the root cause of these discrepancies. Did they stem from receiving errors? Picking mistakes? System issues? When you know the source of the problem, you can implement processes to eliminate it and improve your warehouse inventory control.
Use risk management to plan for the unexpected
Warehouse operations face a wide range of risks from equipment failures to weather-related staffing shortages. Kevin emphasizes the importance of having contingency plans in place before problems occur. That means not just having a plan A and B, but also a C, D, and even E. This might include everything from backup power systems and multiple internet providers to cross-training employees and maintaining emergency procedures.
As warehouses become more dependent on technology, these contingency plans become even more crucial. What happens when your internet goes down, and you can’t use your cloud-based warehouse management system? How do you maintain operations if your automated systems fail? The key is to think through these scenarios and have actionable backup plans ready to initiate at a moment’s notice.
Technology trends reshaping warehouse operations
The warehouse industry is experiencing a technological revolution, driven primarily by labor challenges and the need for greater efficiency. Kevin shares the shift from the once popular concept of “lights out” warehousing to more of a collaborative robotics approach.
The “lights out” movement stemmed from the idea that warehouses would eventually become fully autonomous, requiring little to no human intervention. However, what we’re actually seeing are solutions that augment human workers rather than replace them entirely. This approach makes sense for most warehouse operations because it’s more flexible and doesn’t require the massive upfront investment required by full automation.
There has also been a rise in niche solutions that tackle specific pain points. For example, AI-powered cartonization software that ensures you’re using the right-sized packaging, or systems that optimize picking paths based on real-time variables. These smaller innovations often provide immediate ROI and are accessible to mid-market businesses, which makes them attractive options for SMBs looking to dip their toes into new warehouse tech.
Warehouse quality assurance and safety
Quality assurance varies significantly by product type and value, but the underlying principle remains constant: implement checks that align with your risk profile. Whether it’s weight-based verification systems, computer vision technology, or manual audits, the goal is catching errors before they leave the warehouse.
Safety, however, is non-negotiable. Warehouses are inherently dangerous environments with heavy equipment, elevated storage, and constant movement. Creating a safety-first culture isn’t just about compliance; it’s about protecting your most valuable asset. Your workers.
Ready to optimize your warehouse operations?
These insights from Kevin Lawton represent just the tip of the iceberg in warehouse optimization. From warehouse inventory control best practices to emerging technology trends, there’s a wealth of knowledge waiting to transform your operations.
For even more insights from industry expert Kevin Lawton, watch the full episode of Secret Life of Inventory to discover specific strategies for layout optimization, equipment investment priorities, and dealing with returns.
0 Comments