How Hyundai Powertech Doubled Storage for a New Product Launch
Success Stories in Action
Client Goals and Challenges
Hyundai Powertech needed to optimize warehouse storage at the company’s manufacturing facility in West Point, GA to accommodate additional assembly parts for an upcoming 8-speed transmission product launch.
Limited warehouse space prevented the existing double selective upright rack from storing the additional parts. Materials Manager, Yong Kim, explained the problem well:
“Our 8-speed transmission parts are heavy and very sensitive. Most parts are packed in small plastic boxes and stacked on plastic pallets. The pallets arrive strapped down, but our work process involves us unpacking a portion of the parts and then repacking and racking the rest. These pallets are susceptible to tipping over, so it’s important they are properly secured.”
Considerations We Had to Solve
- Custom level cart pushback system to keep partially packed plastic pallets stable and secure
- Special cart stops to prevent unsafe loading and ensure forklift safety
- Retrofitting Hyundai’s existing rack in Phase II of the project to cut costs while preserving safety and capacity
- Carton flow system added to the bottom level of Phase II bays for picking efficiency
As a solution, Mathand designed and installed a custom, level cart pushback rack configuration from Steel King. This kept the carts and unstrapped pallets flat and secure during loading and storage.
“We recommended a level pushback cart and first pallet position to keep pallets steady, even as the carts move,” explains Matt Davis, a Mathand Product Specialist.
This pushback rack system featured four double bays, four levels high, and two pallets deep, totaling 64 pallet positions to fit the constrained area. Our team also modified some existing selective rack and incorporated a carton flow pick system for added efficiency.
“The pushback rack provides double the storage capacity of selective rack, and 4x floor storage in the same space,” says Davis.
A custom pushback rack system doubled Hyundai Powertech’s storage capacity and improved pallet stability without expanding the warehouse footprint. By using existing racks and integrating carton flow, the solution boosted safety, efficiency, and storage density for the upcoming launch.
Outcomes
- Doubled storage capacity in the same footprint compared to selective rack
- Increased floor storage by 4x compared to floor-stacked inventory in the same area
- 31% more storage than double-sided selective rack in Phase II
- Improved forklift safety with one-sided loading/unloading and custom cart stops
- Increased pallet stability for sensitive, partially packed loads
- Boosted picking efficiency with integrated carton flow system
Real Results. Real Impact.
We’ve done it before — and we’ll do it again. See how Mathand can help you enhance operations, maximize space, and move faster.
