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Push-back Rack is a popular warehouse storage solution providing high-density pallet storage combined with optimal SKU selectivity. The system is comprised of several nesting wheeled carts that ride along slightly inclined rails. Pallets are accessed from a single aisle for loading and unloading, supporting Last-In, First-Out inventory rotation.
Training your warehouse team in proper loading, unloading and maintenance of your push-back system will ensure optimal warehousing productivity.
The first step is to confirm that all forklift operators are properly trained and certified
Second – check the quality of the pallets. GMA style wooden or plastic pallets are well suited for push-back but you must make sure they are in good condition with no loose or missing boards.
Third - Review the product load to ensure there is no load overhang. Also fix any loose cartons, flaps or shrink wrap.
Lastly, make sure to confirm that load weight is within the rated capacity for the system.
The forklift operator should use the following steps to properly load a push-back system.
Lift the pallet approximately 3 to 4 inches above the top cart - enter the rack and place the pallet centered on cart… * then slowly back out.
Next, line up the 2nd pallet with the bottom boards of the first pallet, just above the cart.
Gently push-back the 1st pallet as you enter the rack, centering the 2nd pallet over the exposed cart. Note - if the pallet is not centered correctly, leaving additional space at the front of the cart, you will risk misloading the next pallet. If this occurs - back out of the system and re-load the misaligned pallet.
The last pallet will sit directly on the push-back rails. Once again, center the pallet in the lane and lower it onto the rails behind the pallet stops. If provided in your system, pallet stops can be used to help center the pallet and to absorb impact from rear forces.
You will extract pallets from the same aisle used to load the system.
Once again, center the forklift with the front pallet and slowly enter the lane. Lift the pallet 3-4 inches, so that it clears any pallet stops or obstructions... Then slowly back out. The subsequent loads and carts will roll forward to the aisle face.
Steps are repeated to unload the remaining pallets in the system.
In some cases a bumper plate is installed to ensure a low-impact cart stop, however... the operator should control the speed at which the rear pallets advance by backing out slowing when removing the pallet.
Push-back is a low maintenance storage system - However, there may be times you need to troubleshoot a pallet hang-up. If a rear pallet is stuck, the operator can first try "plugging the system". This is accomplished when the forklift operator uses the front pallet to gently push carts back 2-3 inches before backing out. Usually this will dislodge the hang-up and release the rear carts. However, if plugging the system doesn’t do the trick... stop, replace the removed pallet, and contact management.
In order to manually remove a difficult hang-up, you must 1st fully unload all pallets adjacent to the lane. The operator, secured by a safety harness can then enter the level of stuck carts and first remove the product from the pallet and then dislodge the hang-up.
Check lanes to make they are free from debris, remembering that quality pallets are less likely to splinter and get caught in the tracks. Also, check for loose shrink wrap which can obstruct the flow of the carts.
Bolted connections should be checked for a tight, secure connection that meets proper torque specifications.
Wheel bearings, particularly in situations where they are subject to moisture or liquids, should be tested to make sure they spin freely within the lane.
In cases where you need to enter the system for maintenance or hang-up issues – Once again, unload the bay, along with all adjacent bays. Enter the level only once secured with a safety harness and lift out individual carts to check the wheels and bolted connections.
If you have questions regarding push-back operation or maintenance, call US today - our storage and material handling experts are here to help.
Script #2 - Promo Video
Push-Back Storage Systems provide space-saving, dense pallet storage combined with 100% lane selectivity. Manufactured with durable, abuse-resistant structural steel, our Push-back systems will maximize your warehouse space and productivity by eliminating aisles and reducing forklift travel time.
Unlike Drive-In Rack, each push-back lane can store a unique SKU - standard from 2-6 deep as well as our industry exclusive 7-deep design. Easy, efficient forklift access is achieved with pallets accessible directly at the aisle face for Last-In/First-Out inventory rotation.
Ideal for high volume, high SKU applications, push-back provides more pick faces in fewer aisles, for 90% more storage capacity vs. selective rack in ambient, cooler or freezer facilities.
Here's how it works - Push-back uses a system of nested wheeled carts, on slightly inclined rails within the rack structure. The first pallet load is placed on the top cart using standard forklift equipment.
As the 2nd pallet is loaded, the first pallet and cart are gently pushed back, exposing the 2nd cart. The process continues until the last pallet is placed directly on push-back rails.
Pallet extraction is accomplished in the same manner - As the forklift removes the front pallet, the rear pallets and carts gently flow forward toward the aisle completing the LIFO product rotation. When the lane is empty, all carts are stacked and ready for reloading.
All our Storage systems are manufacturing for long-lasting performance even in the toughest warehouse conditions. Give us a call today- our system experts will design a custom Push-Back System to optimize warehouse space and efficiency.
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