Lean production is a management method that emphasizes efficiency. One of its key strategies is to reduce material storage space. This helps lower inventory costs, ease capital pressure, optimize production processes, and enhance 6S management while reducing safety risks.

I. Cost-Reduction Benefits

1. Lower Inventory Costs

Reducing material storage space forces a reduction in inventory levels. This directly cuts storage-related expenses such as warehouse rent, equipment maintenance (shelves, forklifts, etc.), and labor costs associated with inventory management. For example, a smaller storage area limits the volume of stock, preventing over-purchasing and reducing idle capital tied up in inventory.

2. Reduce Capital Occupation

Lean production promotes efficient capital turnover. With less storage space, companies adopt more precise procurement strategies based on real-time production needs. This avoids overstocking and frees up funds for R&D, equipment upgrades, and other strategic investments, improving liquidity and capital efficiency.

II. Production Efficiency Improvements

1. Streamlined Production Process

Less storage space simplifies the handling and movement of materials. A compact and rational layout allows materials to reach the production line faster. Small and efficient storage designs reduce transportation distances and time, improving the overall production workflow.

2. Increased Production Flexibility

Smaller storage areas make it easier to adjust the storage and supply of materials. When production demand changes, companies can quickly reconfigure the layout and switch between different types of materials. This agility helps businesses respond rapidly to market demands, especially during product transitions or output fluctuations.

III. Quality and Management Enhancements

1. Easier Material Supervision

With reduced storage space, material management becomes more centralized and easier to monitor. Managers can quickly inspect material quantity, quality, and storage conditions. It’s also easier to detect issues such as damaged, expired, or misplaced materials, ensuring the quality of materials fed into production.

2. Lower Risk of Material Damage

Larger storage areas are more prone to environmental influences (e.g., humidity, temperature) and longer handling paths, increasing the risk of material damage. A smaller, well-controlled storage environment shortens transport routes and reduces the chance of loss or damage.

Case Study: Jieermei’s Self-Developed Profile Stacking Rack

Today, let’s take a closer look at a profile stacking rack independently developed by Jieermei, which achieved a rational layout in the raw materials area through vertical stacking. It reduces space waste, improves production efficiency, and enhances 6S management. The workplace is now more organized, and space is utilized more effectively.

The Challenge We Faced

Our company handles a wide variety of profiles, including rectangular tubes, seamless pipes, channel steel, welded pipes, and more—over 30 different specifications in total. Storing such a diverse range consumes a large warehouse footprint. Although stacking could save space, it also increases the time and cost of hoisting when workers need to access specific profiles.

Our Improvement Strategy

To solve this issue, we designed and manufactured three custom profile racks. When materials arrive, entire bundles are hoisted directly onto the racks. Each rack is equipped with a crank handle that allows the operator to slide out individual compartments for easy access. After use, the compartment slides back into place with another turn of the crank.

This design not only solves the problem of space waste due to multiple profile types and specifications but also simplifies the retrieval process. Workers can directly access the required material, saving both space and time.

Summary

From project initiation to implementation, the development of the profile rack took six months. During the design phase, we conducted extensive research, data collection, 3D modeling, and stress analysis. Rigorous calculations and team discussions laid a solid foundation for turning the concept into a tangible product.

Precision was critical in the manufacturing stage—even 1mm deviation in welding or sizing could compromise the sliding mechanism. We used bent steel plates and welded rectangular tubes to ensure exact dimensions and load-bearing capacity.

• A total of three racks were made.
• Total investment: RMB 45,000.
• Occupied area: 60㎡, compared to the previous 128㎡, saving over 50% in storage space.

This fully resolves the industry dilemma of profile storage vs. retrieval, space vs. time.

By improving space utilization and enhancing operational efficiency, the profile stacking rack helps reduce production costs and enables continuous improvement—empowering our customers to achieve their lean production goals and strengthen competitiveness.

At Jieermei, innovations like this are found all over our workshop. In the future, we will continue sharing more outstanding cases through our special columns on Lean Production, Innovation Management, Team Highlights, New Product Launches, and Customer Praise.

Stay tuned for more success stories and practical solutions!