Rack jams caused by unstable or poorly positioned pallet loads has been a problem for some time now. we have about 75 thousand pallet positions in our Canadian distribution center. About 30% of these pallet spots are push back. Until 16 months ago, we would enter jammed locations and manually clear the affected area with only a safety harness for protection at height. Our site safety managers decided to stop employees from entering racks in this manner and as such resulted in 600 pallet positions out of service. We tried several approaches to this problem and ended up with a unit called MARC (maintenance and retrieval cart). Rack inspections and clearing are now part of our daily procedures and I am happy to report zero locations out of service. We have 27 DC locations throughout North America and orders are already being processed in many of our US location. Well worth investigating!
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