Technology Archives - BSE UK Pallet Racking and Shelving Systems, Mezzanine Floors and Interiors Mon, 09 Mar 2026 11:10:15 +0000 en-US hourly 1 https://wordpress.org/?v=6.8.5 https://www.bse-uk.co.uk/wp-content/uploads/2018/12/cropped-bristol-storage-favicon-32x32.png Technology Archives - BSE UK 32 32 Warehouse and Inventory Management: Best Practices for Accurate, Efficient Stock Control https://www.bse-uk.co.uk/pallet-racking/warehouse-inventory-management-best-practices/ Mon, 09 Mar 2026 11:09:09 +0000 https://www.bse-uk.co.uk/?p=86338 When orders are streaming in, forklifts are moving, pickers are weaving through the aisles, and the phones are buzzing with customer queries - it’s a typical start to a busy day for many warehouse and operations managers. “A good problem to have” is commonly heard when reflecting on the operational strain of ‘busy’ periods.  So,…

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Warehouse operatives scanning a barcode on pallet of stock that links to the warehouse management system.

When orders are streaming in, forklifts are moving, pickers are weaving through the aisles, and the phones are buzzing with customer queries - it’s a typical start to a busy day for many warehouse and operations managers. “A good problem to have” is commonly heard when reflecting on the operational strain of ‘busy’ periods. 

So, if you step back and look at the bigger picture of your business’ path of growth, that temporary ‘good problem’ can develop into ongoing pain points. When stock is hard to find or storage doesn’t make sense, every wasted minute shows up on the order log. Good warehouse and inventory management isn’t about counting every pallet - it’s about making sure everything has a place, teams can work without backtracking or bottlenecking, and stock moves through the building efficiently, however high your order intake.

For growing UK businesses, the warehouse is usually where the stress shows first. Orders pile up, stock moves slower, and small inefficiencies quickly ripple through operations. And it all comes back to this: is your space helping your operation run smoothly, or is it holding you back as your business grows?

lorries offloading into a warehouse docking bay

What is warehouse and inventory management?

Warehouse and inventory management is the process of controlling stock from how goods are received, to where they are stored, how they’re picked, and how accurately everything is tracked.

At a practical level, it covers four main areas:

  • Stock control – knowing exactly what SKUs and stock levels you have. 
  • Storage – how and where that stock is physically stored.
  • Movement – how goods flow through the building
  • Accuracy – how reliable your data is compared to reality

Many businesses use a Warehouse Management System (WMS) to support this, giving a real time view of stock levels and locations. A WMS can be powerful, but it only works properly if the physical space makes sense in tandem. If stock locations are unclearly marked, racking layout is inefficient, or access routes are congested, the system ends up reflecting poor processes rather than fixing them as it should.

In other words, warehouse management and inventory management are as much about space design as they are about software.

Objectives of warehouse and inventory management

Warehouse operative standing in a warehouse pallet racking aisle with a picking list

Maintaining stock levels

On the face of it, inventory management keeps a balance between demand and what you have available. Add in the financial benefit of not tying too much cash up in inventory or minimising risk of your storage space becoming a constraint and it’s a dream process. This applies commonly for e-commerce and wholesale businesses where on-demand, fast fulfilment and readily available stock is crucial. 

When stock levels are managed well, businesses can plan their purchasing with confidence, reduce emergency orders, and avoid paying for space they don’t actually need.

Improving order accuracy and fulfilment speeds

Picking speed and accuracy are closely linked to efficient warehouse layout. If stock is logically organised, clearly labelled and easy to access with the right equipment available, picking becomes faster and inaccuracies reduce naturally.

Poor layouts create inefficiencies that may not be obvious at first glance: extra walking distance for pickers, double handling, congested aisles and missed items. Over time, this can lead to slow fulfilment, frustrated teams and unhappy customers.

Reducing waste, loss & overstocking

If anything, lost, damaged or obsolete stock is often a symptom of poor storage design. When products are stored in unsuitable systems or squeezed into the wrong locations, visibility drops and control goes with it.

Effective warehouse and inventory management makes every item visible, accessible and accountable.

Core inventory management practices

 Inventory classification and prioritisation

Not all stock deserves the same treatment. Top tip for any warehouse, particularly those in Third Party Logistics or for online retailers: high-volume, fast-moving items should be the easiest to reach. Slower movers can sit further back or higher up.

This is where storage systems become part of inventory strategy:

Storing products on the right type of system, at the right height, in the right location reduces handling time and physical strain while improving picking accuracy.

Good classification also supports smarter space planning. Fast movers should be close to dispatch. Reserve stock can be further away. Specialist or awkward items should be kept in dedicated zones.

Pallet Racking with weight loading sign displayed on the end with information about safe load capacity for that bay

 Cycle counting & inventory audits

Rather than disruptive annual stocktakes, cycle counting is when checks of small sections of inventory are carried out on a rolling basis. This keeps data up to date and accurate without stopping operations altogether.

Warehouses with racking layouts that suit their specific operation, consistent pick face labelling and clear storage logic find this much easier to maintain because staff always know where stock should be.

Inventory performance metrics

Useful metrics include:

  • Stock accuracy
  • Order fulfilment time
  • Inventory turnover
  • Storage utilisation

Beyond their use for reporting on KPIs, these factors show the true picture of whether your warehouse is genuinely supporting business performance or limiting it.

Storage systems for inventory management

This is where physical space becomes the main driver of performance - getting it right is crucial. 

Pallet racking & structured stock locations

Pallet racking is still the backbone of most warehouses, and for good reason. It provides:

  • Fixed, clearly defined stock locations
  • Good visibility across SKUs
  • Safer handling for heavy loads
  • Support for FIFO stock rotation

When the right pallet racking solution is properly designed, installed and labelled, staff spend less time searching and more time moving stock. That directly improves order accuracy and picking speed.

The key isn’t just having racking, it’s having the right racking layout for your product profile and order flow.

Load management, weight limits and safety

Every storage system has safe weight loading limits. Heavy duty shelving, pallet racking and mezzanine structures must all be installed with clear load signage and maintained through regular inspections both by an internal person responsible and by professional rack inspections on an annual basis.

Overloaded or damaged racking doesn’t just create safety risks. It leads to inaccessible stock, blocked locations and unreliable inventory data.

Using space efficiently for stock control

As businesses grow, the value of every inch of floor space goes up, so wasted space quickly becomes wasted time and money.

Mezzanine floors are one of the most effective ways to increase usable space without relocating. They’re often used for:

  • Light storage
  • Picking and packing areas
  • Offices or quality control zones

Partitions also play a big role in inventory control. Separating fast moving stock from returns, quarantined goods, specialist items or high value items reduces congestion and keeps workflows clean.

Efficient use of space isn’t when you can squeeze more in. It’s about creating layouts that reduce friction between the three pillars of what keeps your operation moving: people, products and processes.

Warehosue mezzanine floor complete with staircase and railings

High-density and semi-automated storage systems

As operations scale, many businesses move beyond standard adjustable pallet racking to improve density, flow and throughput.

High-density manual systems include:

These systems are still manual, but they significantly increase storage capacity without increasing the building footprint.

Semi-automated and fully automated systems come into play when throughput is high and consistency matters:

These reduce manual handling, support faster picking and make stock movement more predictable, particularly useful for time-critical or high-volume operations.

For most growing businesses, the real decision isn’t about full automation. It’s about choosing the right balance between people, layout and technology.

Safety, compliance & maintenance

Why safe storage supports reliable inventory data management

Unsafe or poorly maintained storage leads to:

  • Damaged stock
  • Blocked access routes
  • Unusable locations
  • Inaccurate system data

Regular racking inspections by SEMA Approved Rack Inspectors, clear load signage and maintenance schedules protect both people and inventory.

Accurate inventory data depends on physical reality. If the storage isn’t safe or accessible, the numbers quickly become meaningless.

Practical guidance and tools

The UK Health and Safety Executive provides clear guidance on warehouse storage, racking inspections and safe working practices:

https://www.hse.gov.uk/pubns/books/hsg76.htm

Using inspection checklists, staff training and layout planning tools helps bridge the gap between warehouse design and day-to-day operations.

Storage Equipment Manufacturers Association Full Member with Approved inspector icon and Health & Safety Executive Icon

Keeping your inventory management practices up to date

Warehouse and inventory management isn’t a one-off project. It evolves as your business evolves.

Regular reviews help you:

  • Adjust layouts as product ranges change
  • Add mezzanines or new shelving as volumes grow
  • Reconfigure racking for new order profiles
  • Introduce higher-density systems when space tightens

The most effective warehouses don’t chase trends. They continuously align their space with real operational needs.

When your warehouse supports how your teams actually work, inventory management becomes simpler, more accurate, and far easier to scale.

Expert advice for your warehouse & inventory management

For expert advice on warehouse and inventory management, or to discuss your storage needs, get in touch with the team at BSE UK:

Call: 0117 955 5211
Email: info@bse-uk.co.uk

Our team is ready to help you optimise your warehouse for accuracy, efficiency, and growth.

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]]> PUWER – What Does It Mean For Warehouse Managers? https://www.bse-uk.co.uk/blog/puwer-mean-warehouse-managers/ Fri, 10 Nov 2017 10:38:58 +0000 https://www.bse-uk.co.uk/?p=1214 March 2018 PUWER – What Does It Mean For Warehouse Managers? March 2018 March 2018 ‘PUWER’ or Provision of Work Equipment Regulations 1998 is the regulation set in place to keep people safe when using equipment whilst at work. This includes employers, employees contractors and suppliers. Read our latest blog to find out more about…

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March 2018

PUWER – What Does It Mean For Warehouse Managers?

March 2018

March 2018

PUWER regulations for wareh‘PUWER’ or Provision of Work Equipment Regulations 1998 is the regulation set in place to keep people safe when using equipment whilst at work. This includes employers, employees contractors and suppliers.

Read our latest blog to find out more about PUWER and how you can ensure machinery and working equipment is safe to operate in your warehouse.

Requirements Of PUWER

Under PUWER, warehouse managers will need to ensure that working equipment is safe and suitable for use without posing a risk to the user’s health and safety. The requirements for ensuring work equipment is safe to use include:

  • Equipment is suitable for its intended use.
  • Equipment is maintained in safe condition and inspected regularly.
  • Employees using equipment have received adequate information, instruction and training.
  • Employees are aware of any health and safety measures on equipment such as emergency stop buttons.
  • Equipment is capable of being safely isolated from a power source.

PUWER does not just apply to large businesses, anyone in any sector that controls or is responsible for work equipment has to follow them.

What Constitutes as ‘Work Equipment’ Under PUWER

The HSE defines ‘work equipment’ as any machinery, equipment, appliance, apparatus, tool or installation for use at work. In summary, ‘work equipment’ covers just about anything used by an employee at work – including equipment they bring in themselves.

Additionally, under PUWER, ‘using’ work equipment does not constitute simply operating it; responsible persons will also need to ensure that users of work equipment are safe whilst starting, stopping, programming, setting, transporting, repairing, modifying, maintaining, servicing and cleaning work equipment.

What Can You Do to Protect Yourself and Your Employees?

If you are a warehouse owner or manager, it is your responsibility to manage risks caused by work equipment and their use. Here are a few common risks that may be overlooked in the warehouse, and what you can do about them.

Forklift Trucks – Regular inspection, maintenance and repair is essential for keeping your forklift fleet safe and efficient. You may also consider implementing safeguards such as anti-roll mechanisms, driver restraining systems and racking guards to prevent damage and the risk of collapse in the event of a collision.

Staff training is essential when It comes to forklift operation, you must ensure that the person operating the forklift is properly trained and understands health and safety procedures during use of the forklift.

Corner guard

Racking Systems – Many overlook the fact that pallet racking falls under the category of ‘work equipment’ and thus should be kept in a safe condition. You should aim to have your pallet racking inspected annually by a SEMA approved rack inspector or when damage becomes apparent.

Rack awareness training courses for your warehouse can aid in recognising damage to racking early and increase employee awareness about the risks of damaged pallet racking. Check out our blog to find out 5 ways you can prevent damage to your racking system.

racking inspection SEMA approved

Moving Machinery – Moving machinery carries the potential to cause accidents, whether it is by a projectile, sparks, poor training or a person working in an unsafe proximity to the machine.

Machine Mesh Guards are designed to enclose the machine during operation, to ensure that any flying objects and sparks are contained.

The guard can also be sealed off to prevent any worker entering the enclosure during operation – in any situation, workers should be aware of how to shut down the machine in an emergency.

At BSE UK, we recommend the Axelent X Guard, You can see how it works below:

Lighting – Under PUWER, all employers must ensure that any areas where people use work equipment are suitably and sufficiently lit. Many older style high bay warehouse lights are inefficient, dim, slow to start up and have a short lifespan.

LED lighting is a superior alternative to this type of lighting, requiring fewer bulb changes and reduced maintenance. Additionally, the occupancy detection and zonal control features ensure that operatives always have adequate light when working.

SEMA Approved Pallet Racking Inspections from BSE UK

If you are a warehouse manager, pallet racking inspections can help you stay compliant and prevent system collapses in your warehouse. At BSE UK, we are proud to provide independent  racking inspections across the whole of the UK.

For any information and advice on keeping your racking system compliant, or to book your inspection today – speak to one of our expert team on 0117 955 5211.

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]]> Working with Robots and Not Against Them https://www.bse-uk.co.uk/blog/working-robots-not/ Wed, 31 May 2017 14:14:09 +0000 https://www.bse-uk.co.uk/?p=1082 Working with Robots and Not Against Them Working with Robots and Not Against Them Did you ever see Westworld? The 1973, sci-fi set in your not so typical amusement park where the rich get to live out their fantasies though artificial consciousness. You know, the one where in the end the robotic “hosts” malfunction and…

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Working with Robots and Not Against Them

working with robots and not against themWorking with Robots and Not Against Them

Did you ever see Westworld? The 1973, sci-fi set in your not so typical amusement park where the rich get to live out their fantasies though artificial consciousness. You know, the one where in the end the robotic “hosts” malfunction and take over the park spreading chaos and fear.

It is clear that the fear of robotics integrating into everyday life is nothing new; something science fiction authors have predicted for years. Although not quite as dramatic, the real fear is that they aren’t, in fact, coming for you, but for your jobs.

But in actual fact, it is likely that advancements in technology and automating jobs within the workplace can benefit businesses and employees alike. But how, we hear you say. Find out below:

The Age of Automation

Some may say that implementing robotics in warehouse operations is nothing new, after all “dumb robots” have been used for some time now for performing repetitive tasks.

However, many are converting to improved automation in an attempt to stay competitive or to gain an edge over competition. As such we are seeing – from businesses at least – a widespread acceptance and presence of robots in warehouses and logistics operations. In fact, Tech Republic suggests that chain operations will go from 40,000 units (2016) to a projected 620,000 by 2021.

It seems that increasingly companies are coming to the conclusion that “hybrid” scenarios make a lot of sense whereby workers effectively manage, programme, and maintain robots across the warehouse in order to improve both productivity and performance.

In effect, a factory or warehouse that saves money on labour through automation will lower prices which make its products more appealing and creates an increased demand that may lead to the need for more workers. In turn, a greater profit will enable the pay of higher wages.

If you’re still not convinced just take a look at those who are already doing it;

Amazon

Over the last three years, Amazon has increased the number of robots working in its warehouses from 1,400 to 45,000. Over the same period, the rate at which it hires workers hasn’t changed.

Some have suggested that robots help Amazon keep prices low which means that the company needs more people to man its warehouses even though it requires fewer human hours of labour.

Locus Robotics System

A Massachusetts-based start-up developed a new multi-robot fulfilment system at the facility of its development partner, Quiet Logistics. The robots and warehouse associates work together in a manner designed to reduce travel time and increase productivity.

Associates scan items and place them into totes that are transported by the robots. They autonomously navigate through the warehouse infrastructure along with others in the fleet.

Ocado

In its Hampshire distribution centre, traffic management systems are in place to help with every day activity. Instead of all the conveyors, cranes, and big machines they instead have swarms of robots collaborating with one another to collect customer groceries and bring them to the point where they’re picked.

Improving Your Warehouse Processes

It is clear that technology is radically changing the way in which we can expect to work. Whether you’re adopting full automation or indeed pallet racking, mezzanine floors, or workbenches, make sure you get in touch with the team.

Give us a call on 0117 955 5211 for more information.

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