Storage System Improves Efficiency for Maintenance and Repair Operations

Maintenance and Repair Operations (MRO) is central to just about every type of manufacturing facility -- with responsibilities that usually encompass both facilities maintenance, and machine repair and maintenance. An organized, smooth-running MRO department can keep an entire company operating efficiently, while an MRO department that is disorganized, inefficient and ineffective can have negative ramifications that touch just about every aspect of a business -- from overall productivity to employee safety to the bottom line. Disorganization means employees can't find the items they need when they need them. It is also a direct link to inaccurate inventories, unscheduled downtime, unexpected stock-outs, overcrowded or inefficient use of space, and malfunctioning or non-functioning machinery.

If disorganization is causing a problem for an MRO department, an improved storage system is a likely solution. According to John Alfieri, vice president of Lista International, a leading manufacturer of storage and workspace systems, the benefits of implementing an advanced hardware and software storage system are many, and can include:

• Greatly reduced downtime (with predictive and preventative maintenance)

• A more efficient and productive workforce

• Improved operator safety (with machines and equipment functioning properly)

• Fewer product defects

• Lower inventory costs (greater visibility eliminates repetitive and/or blanket work orders; increased organization allows for the stocking of min/max quantities with reorder points)

• Faster and easier inventory process

• Faster parts picking, and improved ergonomic access to more items with less operator movement and strain

• Improved use of valuable floor space

• A more aesthetically pleasing environment and more professional image

In general, there are three types of storage systems that an MRO facilities manager can consider: conventional, automated and high density.

Conventional Storage

Conventional storage, with principle components that include shelving, racks, bins or some variation of these elements, is most appropriate for large bulky items and items that are slower moving. Large quantities of products that do not require daily access and/or are stored and distributed in bulk are examples of items well-suited for conventional storage. Pallet racks are used for items that are delivered on pallets or are very heavy and need to be moved by a forklift.

Automated Storage and Retrieval Systems

This category includes horizontal and vertical carousel and lift systems, and control software. These systems store a lot of items in a relatively small footprint, particularly the vertical systems. Vertical systems also offer exceptional security access, and so are well suited for the storage of valuable and/or limited access items. But vertical systems are expensive upfront and can have a high maintenance price tag. These are machines with moving parts, and carousels require a precisely balanced weight flow, so by their very nature they have a potential to break down. They can slow down stocking and retrieval, as they also only allow access and picking by one operator at a time.

High-Density Storage

This is the ideal solution for storing medium- to small-sized items. According to Alfieri, modular, high-density storage is unmatched in terms of efficient organization and value. This category includes modular drawer storage cabinets, mobile cabinets and combination drawer/shelf systems such as Lista's Storage Wall® System. It also includes systems that feature sub-dividable drawers as their centerpiece. High-density storage is an ideal solution for an MRO department's disorganization, and offers abundant benefits that conventional storage simply can't -- from complete use of cubic space to load capacity. High-density storage is also more affordable than automated systems. In short, it is the most effective and cost-effective option. Both high-density and conventional storage can be stacked or used in mezzanines to take advantage of a room's full height while making maximum use of floor space. This can be a relatively expensive alternative to building an additional floor.

Another alternative is mobile cabinets. "Mobile modular drawer storage cabinets deliver all the flexibility and completely organized storage of high-density cabinets, while adding the benefit of complete convenience," said Alfieri. With these mobile units, tools and parts can be rolled out directly to the job where they can be readily accessible to maintenance and repair personnel. These mobile workstations-on-wheels can be customized with the particular tool sets used by each craft.

Preventative and Predictive Maintenance

Preventative and predictive maintenance are essential for the efficient running of an MRO department. Both rely heavily on organized storage. The main objective of preventative maintenance is to monitor things before they break. Preventative maintenance is either calendar-based, on a regular time schedule, or position-based, according to the actual position of the equipment.

"The goal of predictive maintenance is to anticipate failures before they happen," said Alfieri. It incorporates various tests, such as vibration analysis and thermo graphic scanning of potential wear points, to predict likely failures. Maintenance is then performed accordingly.

Both of these maintenance procedures rely on precise timing and immediate parts access. This is where advanced storage solutions, and specifically high-density storage, can be so important.


Lista International Corporation,

106 Lowland St., Hoillston, MA 01746

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