Client Overview
A regional online retailer operating across a major domestic marketplace platform runs a 2,000㎡ fulfillment center shipping daily to consumers nationwide. The warehouse manages 4,500+ SKUs — small electronics accessories, home goods, apparel, and promotional bundles. With order volumes fluctuating between 800 and 3,500 parcels per day, the existing floor-stacked cartons and mismatched second-hand
shelves created daily bottlenecks in picking and packing.
The Challenge
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Cartons buried in floor piles: Fast-moving items were stacked two and three deep on the ground. Pickers had to move multiple boxes just to reach one at the back, slowing every order.
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Inconsistent shelf heights: A mix of old shelving units from different sources meant incompatible levels — some too tall for small items, some too short for stacked cartons. Staff couldn't reconfigure layouts when product mix shifted.
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Excessive picker walking: No structured zones. Pickers crisscrossed the entire floor for a single multi-item order, averaging 7 km per shift.
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Wasted vertical space: 5.5 m clear height, but shelves capped at 2.4 m. Upper wall space sat empty while floor aisles narrowed during peak sales events.
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Pick errors and returns: Unmarked locations and visual confusion led to wrong-item shipments, driving return rates above 3% — hurting the store's platform rating.
Shibang's Tailored Solution
Shibang analyzed the top 1,000 SKUs by order frequency, carton dimensions, and daily pick volume, then delivered a medium-duty shelving system built for high-velocity e-commerce fulfillment:
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Medium-Duty Boltless Shelving: 300 kg/shelf rated units with reinforced decks and locking connectors. No tools needed for assembly or reconfiguration — staff can resize bays between sales seasons in a single shift.
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Adjustable Shelf Pitch (50 mm): Shelf heights reset on demand to fit everything from shallow polybags (100 mm) to double-stacked cartons (500 mm), maximizing every bay's vertical envelope.
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Zoned Pick-Face Layout: ABC analysis split the warehouse into three zones — hot items at waist-to-chest height on mid-level shelves for fastest access; warm items on adjacent levels; cold/slow movers on top and bottom tiers.
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Five-Level Vertical Build: Extended to 4.5 m, adding two extra levels over the old setup and increasing pick-face positions by 48% within the same footprint.
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Integrated Small-Bin Row: Top-level color-coded bins capture loose items (cables, adapters, accessories), keeping them visible and separated from main cartons.
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Clear Labeling System: Every shelf position carries a structured location code synced to the client's WMS, eliminating "phantom inventory" and pick errors.
Results & Impact
✅ 50% faster average pick time per order line
✅ Zero shelf deflection at 4-month check
✅ 48% increase in effective pick-face capacity
✅ Picker walking distance cut by 40% via zoned layout
✅ Return rate dropped from 3.2% to 1.1% (fewer wrong-item shipments)
✅ Peak-season ready — extra shelf levels absorb sales-event surges without floor stacking
"Before Shibang, our busiest days meant chaos — boxes everywhere, pickers running in circles. Now the racking actually guides the workflow. Hot items are right where your hands reach, everything is labeled, and we can reconfigure shelves between campaigns without calling a contractor."
— Warehouse Manager, E-Commerce Fulfillment Center
Why Choose Shibang Racking?
18+ years delivering light-, medium-, and heavy-duty
racking across e-commerce, textiles, apparel, printing, automotive, and 3PL. We design around
your order profile, your pick velocity, and your peak swings — adaptable, durable, and built to scale with your sales.
