The Sleep Company

Project Overview

Our project with The Sleep Company- India’s leading sleep-tech (mattress and furniture manufacturers) company, revolutionizing the comfort industry, involved handling SKUs with odd dimensions and uneven sizes.

These included:
• Raw Material SKUs: Fabric rolls, foams, and bed frames.
• Finished Goods: Smart Grid mattresses, pillows, recliners, and assorted furniture.

Pallets and Cage Pallets Design:

By analysing the dimensions of all SKUs, we designed a Unit Load Device (ULD) to accommodate these irregular sizes, and designed 6 wooden pallet varieties (1400 x 1300 mm, 2000 x 1200 mm, 2400 x 2000 mm, 2000 x 2000 mm, 2400 x 1200 mm, 1200 x 1200 mm) to cater to all SKUs, along with one cage pallet (1200 x 1800 mm) specifically for large mattress rolls.

Once the pallet specifications were finalised, our pallet vendor developed prototypes and tested them in real-world conditions before proceeding with full-scale production.

Material Handling Equipment (MHE) Adaptations

However, simply designing custom pallets wasn’t enough—we needed Material Handling Equipment (MHE) capable of handling these irregular SKUs, which was the primary challenge. To address this, we reach out to both Indian and global MHE manufacturers, explaining the requirements and assisting them in customising the equipment.

Key modifications included:
• Widening the fork carriage for improved load stability.
• Adding fork extensions to accommodate larger pallets.
• Introducing straddles on forklifts to enhance fork stability.

According to our MHE vendor, these modifications were first-of-their-kind in India’s mattress industry. An Indian MHE manufacturer took on this challenge, showcasing a strong commitment to innovation, and successfully designed and delivered the customised solution.

Customised Storage System & Aisle Space Optimisation

Designing an efficient storage system and aisle space was another challenge due to the irregular pallet sizes. Since these weren’t standard pallets, there was no prior data on the required aisle space.

To solve this, we worked closely with our racking vendors to develop customised SPR (Selective Pallet Racking) systems with additional components. Additionally, we collaborated with Hyster Yale Materials Handling (our MHE vendor), who shared the project specifications with their German office. After thorough research, they provided the optimal aisle space requirements for handling these customised pallets efficiently between two racks.

Results and Impact

Optimised Storage Capacity: By designing a solution to store and handle odd-dimension and uneven SKUs, we successfully implemented a high-rise pallet storage system, significantly improving cube capacity utilisation in the warehouse.
Enhanced Handling Efficiency & Safety: The shift to mechanised handling methods improved both speed and safety, reducing manual effort while increasing operational efficiency.
Improved Productivity: The synchronisation of Man, Material, and Machine led to a notable boost in workforce productivity.
Designed a metal cage pallet suited to handle long length rolled mattresses and cage trolleys for cut fabric covers, which were otherwise handled manually.
Better Inventory Management: The introduction of cage pallets streamlined inventory counting by enhancing barcode visibility, allowing for quicker and more accurate stock verification.
Optimised Order Picking: The cage pallet design improved SKU visibility from a distance, making order picking faster and more efficient.
Ergonomic design of workstations coupled with right planning and placement of hygiene facilities, utilities, enhancing good working conditions that improve worker morale.
Signage at right places to aid ease of identification, directional guidance, enable information, avoid confusion, and reduce potential risks.
Dedicated, specified, and demarcated spaces for all the equipment and activities, avoiding material contamination, operator confusion, and enhanced operational productivity.

Sustainability Efforts

Our initiative aligns with sustainability goals by enhancing operational efficiency and minimising environmental impact:
- Reduction in Human Effort: Automation and optimised processes reduce manual labour, improving efficiency and workplace ergonomics.
- Green Building Compliance: The facility is designed to meet IGBC Platinum standards, ensuring sustainable construction and operations.
- Efficient Resource Management: Implemented robust scrap, return, and waste management systems to minimise material wastage.
- Energy Efficiency: The entire facility features an energy-efficient lighting system integrated with natural roof lighting to reduce power consumption.
- Climate-Responsive Design:
- The roof has a high Solar Reflective Index (SRI) to reduce heat absorption.
- Thermal insulation enhances indoor comfort by maintaining stable temperatures.
- The ventilation system is designed for 6 to 8 air changes per hour, ensuring proper air circulation.
These sustainability-driven initiatives not only reduce our environmental footprint but also enhance operational efficiency and employee well-being.

Conclusion

This project successfully addressed a unique logistics challenge, establishing a new industry benchmark for handling SKUs with odd dimensions and uneven sizes. Through tailored palletization, MHE adaptations, and storage system customization, we enhanced operational efficiency, setting a precedent for future innovations in warehouse management for non-standard SKUs.