Présentation du Projet

Ce projet à Dongguan pour SouthForge Hardware portait sur a hardware plant handling dies, fasteners, metal fittings, boxed tools, and palletized semi-finished goods. L’objectif n’était pas seulement d’ajouter des rayonnages, mais de créer un système améliorant capacité, sécurité et vitesse d’exploitation.

Runda Rack reviewed the movement of goods, staff routines, available space, load requirements, and the points where time was being lost. The final design focused on heavy-duty pallet racking, mold storage zones, impact guards, wide forklift aisles, and safer separation of people and equipment.

Client et Contexte du Marché

In China’s dense commercial and industrial environment, every square metre must work harder. SouthForge Hardware needed a rack system that could support change, reduce daily friction, and remain clear for staff, shoppers, inspectors, or forklift operators.

The project therefore required more than standard shelving. It needed a layout logic that could support seasonal changes, campaign peaks, replenishment, cleaning, audit control, and future expansion.

Le Défi

Le principal défi était que legacy floor stacking made weight distribution unpredictable, damaged cartons, and forced forklifts to reverse in tight mixed-traffic areas. This issue affected productivity, safety, inventory control, and the quality of presentation or storage.

The site also had to keep operating. Existing stock, deliveries, customers, forklifts, production shifts, or sanitation windows had to be respected during installation.

Solution d’Ingénierie

La solution retenue fut high-capacity frames, beam levels matched to pallet families, floor anchors, end-of-aisle protectors, and a quarantine zone for overweight or irregular loads. Heights, depths, finishes, protection accessories, and label positions were selected according to the real flow of products and materials.

The layout separated high-frequency and low-frequency areas, clarified display, reserve, inspection, and dispatch positions, and reinforced zones exposed to impact, humidity, or heavy handling.

Installation et Livraison

The factory stayed in production while aisles were opened in phases; old floor stacks were cleared, inspected, relabeled, and moved into assigned rack positions. Components were sorted by zone and numbered so installation crews could move quickly from unloading to assembly.

Critical areas were completed first. After each phase, the team checked replenishment, picking, cleaning, customer circulation, or forklift routes before migrating the next zone.

Impact Commercial

The project reduced forklift congestion, made load limits visible, protected operators from unstable stacks, and created capacity for seasonal raw-material purchasing. The result was not only more capacity, but better control of the whole operating environment.

Les indicateurs clés sont Pallet Positions +41%, Forklift Congestion -30%, Load Safety Compliance 100%. These figures show that storage capacity becomes valuable only when teams can use it quickly, safely, and consistently.

Valeur à Long Terme

SouthForge now has a safer heavy-storage platform that can absorb production peaks without returning to uncontrolled floor stacking. The client now has a clearer standard for future upgrades and site planning.

Pour Runda Rack, ce cas démontre que chaque site exige une conception spécifique, et non une spécification générique.