Client Overview
A local third-party logistics (3PL) provider operates a 5,000㎡ distribution hub serving a rotating mix of consumer goods, hardware, and promotional product clients. Inventory arrives in cartons, totes, and small bundles — mostly hand-picked rather than pallet-moved. With client rosters changing every quarter and SKU counts swinging from 800 to 3,000, the warehouse needed
shelving that could adapt fast without a forklift overhaul.
The Challenge
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Inconsistent shelf quality: A patchwork of second-hand racks from different suppliers meant mismatched heights, wobbly frames, and incompatible beams. Staff couldn't reconfigure bays when a new client onboarded.
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Carton overhang & sag: Standard 600 mm deep shelves couldn't comfortably hold 500×400 mm cartons without overhang; stacked two-high, the bottom cartons crushed. Loads exceeding 250 kg caused visible shelf deflection.
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No pick-face zoning: Cartons were stacked deep on open floors during peak weeks, burying slower movers behind fast movers. Pickers walked 6+ km per shift just locating items.
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Wasted wall height: 6.0 m clear height, but existing units maxed at 3 levels (~2.8 m). Upper wall space sat empty while floor aisles narrowed.
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Client complaints: Misplaced cartons and pick errors chipped away at the provider's service-level score, threatening contract renewals.
Shibang's Tailored Solution
Shibang assessed inbound carton profiles, pick-frequency distribution, and the provider's need for rapid reconfiguration, then delivered a medium-duty
shelving system built for flexibility:
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Medium-Duty Boltless Shelving: 300 kg/shelf rated units with reinforced steel decks and locking connectors — no tools required for reassembly. Staff can dismantle and relocate bays in under an hour when a client's contract ends.
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Adjustable Shelf Pitch (50 mm): Shelf heights reset on demand to fit everything from shallow totes (150 mm) to tall cartons (500 mm), maximizing every bay's vertical envelope.
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Five-Level Vertical Build: Extended to 4.5 m with a safe picking height, adding two extra levels over the old setup and increasing storage positions by 42% on the same floor footprint.
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Zoned Pick-Face Layout: Fast-moving SKUs placed on mid-level shelves (waist-to-chest height) for ergonomic access; slow movers on top and bottom tiers. Each bay labeled with client name and velocity tier.
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Integrated Tote Bins: Top-level bins capture small loose items (samples, accessories, spare labels), keeping them visible and off the main pick shelves.
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Powder-Coat Finish: Light blue RAL 5012 coating for easy dusting and a clean, professional look for client walkthroughs.
Results & Impact
✅ 48% faster average pick time per carton
✅ Zero shelf deflection or connector failure at 4-month check
✅ 42% increase in effective storage positions within the same footprint
✅ Picker walking distance cut by 35% via zoned layout
✅ Zero misplaced-carton incidents post-WMS location mapping
✅ Client retention improved — on-time-in-full score rose from 94% to 98.7%
"The old racks were a patchwork nightmare. Shibang's system just works — we reconfigure bays between client changeovers in a morning, and our pickers aren't wasting steps anymore. Clean, solid, no drama."
— Operations Manager, 3PL Logistics Provider
Why Choose Shibang Racking?
18+ years delivering light-, medium-, and heavy-duty racking across warehousing, textiles, apparel, printing, machinery, and e-commerce. We design around your inventory profile and your throughput — adaptable, durable, and built to scale with your business.
