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Each month, our print newsletter Distribution Center Management provides in-depth information and ideas to help readers better manage the warehouse or distribution center.

But we often have valuable background material, additional information, or related resources that we just can’t fit in the newsletter. Listed below are a wide range of documents that add further insight and understanding to the articles in Distribution Center Management.

These documents may be viewed and printed with the Adobe Acrobat Reader. You may download a free copy by clicking on the yellow icon.

Learn more about the Distribution Center Management newsletter.

February 2012

Get out of fire-fighting mode and improve your operations — With all the talk of high-tech efficiency measures, it would be easy to assume that most distribution centers operate efficiently and effectively. But such an assumption would be wrong, says Jeroen P. van den Berg, head of Dutch firm Jeroen van den Berg Consulting and author of the new book Highly Competitive Warehouse Management. Read van den Berg’s white paper A Growth Path for Warehouse Optimization.

January 2012

Fuel costs promise to remake distribution patterns, real estate experts say — Shenzhen’s fast ascent from backwater to distribution hub illustrates how quickly economic forces can change the geography of supply chains. And it’s the sort of example Sam Foster of Jones Lang LaSalle points to when he predicts that the United States’ distribution patterns are poised to change. Read the Jones Lang LaSalle report on changing patterns and emerging hubs.

December 2011

For order-picking warehouses, multiple cross aisles can boost efficiency — To help DCs decide how best to lay out their facilities, Kees Jan Roodbergen of the University of Groningen in the Netherlands designed an online tool that’s available at www.roodbergen.com/warehouse/index.php. Also click to read his white paper on picking layout.

Looking for a more efficient warehouse layout? Maybe the Flying V, fishbone, or chevron are for you — Kevin Gue and Russ Meller have teamed up to question the assumptions behind the traditional warehouse layout, and they’ve found that modifying the layouts can cut travel times by as much as 20 percent. See alternate layouts from Gue and Meller.

Five reasons WMS in the cloud might work for you — See HighJump Software’s WMS in the cloud white paper.

November 2011

Is it time to modernize? Instead of moving, DCs decide to upgrade, overhaul — Many companies are choosing to squeeze as much as they can from their existing warehouses and equipment rather than moving to larger or more modern facilities. To do this, they are tackling process improvements and engineering modifications as well as maintaining and rebuilding existing equipment rather than replacing it. Ken Ruehrdanz of Dematic Corp. provides a useful modernization checklist.

Electric lift trucks much cheaper than propane trucks, and some laggards make the switch — Electric lift trucks are the dominant type of forklift used in distribution centers, with a small number using liquid propane (LP) trucks. DCs looking to reduce operating costs would be wise to replace their LP trucks with electric, says Carl Modesette of Cat Lift Trucks. See Modesette’s white paper Choosing Electric Lift Trucks Over Internal Combustion.

September 2011

Real estate market still favors tenants in most U.S. cities — Despite a slight uptick in demand for distribution space, the market remains soft. For DC operators looking to lease new space or to renegotiate terms on current space, the outlook is favorable. To read the complete Spring 2011 Jones Lang LaSalle industrial real estate report for North America, click here.

August 2011

Find untapped savings by improving operations in your battery rooms — Inefficient use of forklift batteries costs the materials handling industry an estimated $260 million a year. Click here to see Harold Vanasse’s tips for running a lean battery operation.

Logistics costs spike, trucking shortage looms, CSCMP study finds — According to the Council of Supply Chain Management Professionals’ 22nd Annual State of Logistics Report, business logistics costs rose to 8.3 percent of U.S. gross domestic product in 2010, up from 7.7 percent in 2009. Read the full report now.

Tips for preventing cargo theft — The May theft of a trailer-load of Pfizer drugs in Memphis was just one more example of the growth industry in cargo theft, which exacts a $30 billion a year toll. Read the National Insurance Crime Bureau report on reducing theft.

July 2011

Cross-docking gains popularity in difficult economy — Cross-docking isn’t new, but it’s gaining newfound interest from companies that want to shorten their shipping cycles, rein in inventory carrying costs, and deliver just-in-time service — all without making a big investment. Learn about common practices, biggest challenges, and emerging trends in cross-docking in this while paper from 3PL Saddle Creek.

June 2011

Cross-training, communication among simple steps for creating ‘worker-centric’ warehouse — The worker-centric warehouse movement started at the end of the economic boom, when low unemployment rates forced DC managers to think about how to attract and keep workers. Read Kevin Gue’s manifesto on worker-centric warehouses.

May 2011

Trucking company says vigilance, communication key to thwarting thieves — By all accounts, cargo theft is a growth industry. Yet trucking company Schneider National says it managed to cut theft in 2010. A recent white paper explains how.

DCs with automation are satisfied, but cost remains a barrier — Fully 86 percent of warehouses and DCs that have automated material handling are satisfied with their systems, according to a survey by the Integrated Systems and Controls Council of the Material Handling Industry of America. Read the full survey here.

April 2011

Inexpensive software leads to more efficient delivery schedules — See additional information on how Appointment-Plus streamlined Georgia-Pacific’s scheduling.

March 2011

Boost efficiency by reworking existing buildings — In this PowerPoint presentation, Sport Supply Group and TranSystems explain how they boosted efficiency at a cramped facility without an expensive relocation.

WERC certification — See a sample audit from WERC’s new Warehouse Certification Program.

Racking Up Savings with the Right Slotting Strategy — KOM International offers tips for making the most of a reslot in this white paper.

February 2011

The Boyd Co.’s annual DC cost report — Millions of dollars a year in operating expenses separate North America’s priciest and cheapest places to run a distribution center. Read a summary of the report.

Are you prepared for the supply chain talent crisis? — Read the MIT white paper.

January 2011

Energy-Efficient Lighting Guide — Arizona Public Service created this useful guide to the full range of lighting types and money saving options for commercial buildings.

A new generation of picking tools promises more productivity and fewer injuries — See the EcoPick, Vaculex Vacuum Picker, and Destuffer.

Grant Thornton’s annual supply chain survey — The supply chain industry expects profits to improve in 2011. Read the full report, The supply chain today: Achieving efficiencies, managing uncertainties.

December 2010

Rooftop Solar Plant Photos — Warehouse landlord Heller Industrial Parks has gone on a solar building spree in New Jersey. The company produces 1.5 megawatts of solar power at its 8.5 million-square-foot facility in Edison Park.

Rooftop Revenue — Read the research report from the National Association of Industrial and Office Properties Research Foundation.

Supply Chain Information Sharing and Analysis report — View the full report, which includes data on thieves targeting empty tractor-trailers to be used later in cargo theft.

As marijuana harvest season approaches, keep an eye out for shipments of illicit drugs — An archive article from Distribution Center Management.

November 2010

Crowd Engineering — Old-style time and motion studies continue to have a role in the DC and warehouse as this article from Steve Mulaik shows.

Going Green While Watching the Bottom Line — A case study from United Natural Foods.

Annual Survey of Third-Party Logistics — CEOs involved in this year’s survey are more optimistic about growth prospects than they were last year, but appear to be more cautious about how growth will be achieved.

August 2010

Tabletop Disaster Test — The Small Business Administration encourages planning for emergencies and testing those plans with a tabletop drill.

National Industrial Index — Warehouse rental rates will slide in 2010, while vacancy rates will rise, says commercial real estate brokerage Marcus & Millichap.

June 2010

Safety Postcards — At UniFirst Corp. safety is a 24/7 job. So workers receive safety postcards at their homes. Some cover work-related topics, others focus on general safety.

Efficient Packaging — The right packaging can help your organization go green and lean. Terry Harris of Chicago Consulting explains how.

May 2010

Cargo Theft Report — What are thieves’ favorite targets? This report by LoJack Supply Chain Integrity and the Supply Chain Information Sharing and Analysis Center gives the rundown for the first nine months of 2009.

March 2010

Operating Costs — The Boyd Co. ranks dozens of markets based on the costs of running a 450,000-square-foot DC. San Francisco is the priciest, while Jackson, MS, is the cheapest. See where other markets rank.

Retail Supply Chain — See the Retail Industry Leadership Association’s report on managing costs in the supply chain.

West Coast Diversion — Slowly but surely, imports are arriving through the East Coast and Gulf Coast rather than the West Coast. See Grubb & Ellis’ chart illustrating this trend.

February 2010

Go Green Sources — Before the economy took a turn in late 2008, green initiatives were all the rage. And while sustainability hasn’t dropped off the radar yet, most companies are looking for initiatives that are both green and help reduce costs at the same time. According to Lou Cerny, a vice president at consulting firm Sedlak, changes to exit signs, urinals and cartons can make a difference.

Packaging Sustainability Report — The future is bright for sustainable packaging, according to a Tompkins’ Supply Chain Consortium survey of top retail- and manufacturing-related companies. (Online registration required.)

January 2010

The Worker-Centric Warehouse — Sponsored by the Material Handling Industry of America, Dr. Kevin Gue and his associates are conducting a survey of warehouse workers to determine their level of satisfaction in different areas. Read their manifesto here.

Walgreens’ Anderson, SC, DC — 30 percent of the workforce at a Walgreens DC in Anderson, SC, is made up of people with disabilities. These employees have been trained to work side-by-side with other team members, with the same productivity goals, earning the same pay. Watch a video of the Anderson, SC, DC in action here.

Conveyor Safety Resources — Conveyors can be one of the best productivity-enhancing tools in today’s DCs, but injuries cost U.S. employers millions of dollars every year. That’s money you can save and pain you can avoid with the right processes and design. These resources can help you upgrade conveyor safety in your own facility:

• Conveyor Safety Poster (PDF document courtesy of Cisco-Eagle and Hytrol Conveyors): This printable poster can be posted in break rooms and conveyor area to reinforce training.
• Conveyor Safety Manual (PDF document): Printable conveyor safety standards from Cisco-Eagle and Hytrol Conveyors, Inc.
• Conveyor Safety Tips from The U.S. Department of Labor. Some tips on belt conveyor safety.
• Concepts and Techniques of Machine Guarding. Information from OSHA on machine guarding techniques.

Forklift Accident Brings Down The Warehouse Video — Need another reason to implement forklift safety procedures in the DC? Watch this YouTube footage of a forklift accident that literally brings the warehouse down.

December 2009

Green Roofs — Is a green roof right for your DC? This article by Tecta America’s Mark Gaulin can help you decide.

Rubber Pallet Bands — U.S. Foodservice-Fort Mill’s DC was able to save $8,000 in five months by replacing shrink wrap with rubber pallet bands. The DC has also seen a reduction of more than 100,000 pounds of shrink wrap per year. Here is a list of some of the many manufacturers and distributors of rubber pallet bands.

Inventory Management Seminars — These seminars, led by the Distribution Team’s Jason Bader, teach more than 30 different “hunting for cash” ideas that DC managers can implement immediately. All aspects of purchasing, inventory management, warehouse operations, branch operations, receiving and put away, cycle counting, dead stock management, and distribution industry technology are covered. To learn more about these seminars, visit The Distribution Team’s website.

November 2009

Is Fear of Benchmarking Costing you Money? — Consultant Debra Ellis says one of the best ways to identify inefficiencies in your picking process is to implement a benchmarking system. But if the idea of benchmarking is a bit daunting, remember that not doing it could cost you money. Want help getting started? This article by Ellis can help.

Mezzanine Flooring Case Studies — Choosing the right flooring for a mezzanine in your DC can be tricky business. Read these case studies to learn how other DCs have made that choice.

Fundamentals of a Workplace First-Aid Program — A good first aid program is an important part of any health and safety plan, according to the Occupational Safety and Health Administration (OSHA). Having a first aid plan in place can help reduce lost-time injuries and help workers recover faster. Get a jump-start on creating your workplace first aid program with this document from OSHA.

October 2009

Advanced Energy Design Guide — The U.S. Green Building Council, in association with a number of other organizations, is offering an Advanced Energy Design Guide series of publications as free electronic downloads. One publication in the series offers advice for warehouse buildings to reduce energy usage by 30 percent. (Registration is required.)

AC Electric Versus Internal Combustion Forklift Trucks — Should you choose a three-phase AC electric forklift truck or a more traditional internal combustion truck? This whitepaper from Jungheinrich Lift Truck Corp. can help you decide.

September 2009

Nine Signs Its Time to Replace Your WMS — Is your WMS outdated? This whitepaper from HighJump software offers in-depth information on how to tell if you need a new WMS.

Tips for a Healthy Spine — Approximately 80-90 percent of the population suffers from spinal pain at some point. People who lift heavy objects are more likely to experience back pain, which puts DC workers at risk. This paper from the American Chiropractic Association can help teach both you and your employees about the importance of having a healthy spine.

August 2009

Lean Readiness Quiz — Are you ready to go lean in your DC? Or are you already lean? This quiz from Lean Cor LLC can help you determine your company’s current lean logistics and supply chain management levels.

Video Image Detection — Video image detection uses cameras to detect the presence of fire and/or smoke in the DC, providing faster detection times than conventional detectors. Watch this video from axonX LLC to see video image detection in action.

July 2009

Pandemic planning resources — The Centers for Disease Control is continuing to investigate human cases of H1N1 flu in the United States and is working closely with Canada, Mexico and with the World Health Organization. As part of its response to the outbreak, the CDC is issuing new H1N1 flu guidance, now available online.

World Health Organization updates — The World Health Organization offers a number of resources and updates on the H1N1 flu virus on its website.

Advanced pandemic planning whitepapers — These whitepapers by Regina Phelps, principal of EMS Solutions, offer advice for executives in a number of industries on how to properly prepare pandemic plans.

June 2009

Overcoming the Challenges of Split Case Picking — Learn how to implement automated split case picking solutions in this whitepaper by Diamond Phoenix CEO Tom Coyne.

What Is the Storage Utilization Factor? — The Storage Utilization Factor (SUF) is one of the least understood terms in warehousing. As such, it is also one of the principles of warehousing that causes the most operational problems for companies. This whitepaper by Fred Kimball of Distribution Design helps clear up the confusion about the SUF.

May 2009

AS/RS System Videos — Automated storage and retrieval systems can help a DC optimize material flow, reduce costs, and decrease labor requirements. Watch video of an AS/RS in action on the Westfalia website.

Taking Difficult Conversations “Seriously” — Larry Johnson, consultant and author of Absolute Honesty: Building A Corporate Culture That Values Straight Talk and Rewards Integrity, writes about how to discuss those tough issues with employees.

April 2009

Driving Higher Workplace Performance — Bruce Ennis, a Lean Six Sigma Black Belt, was assigned the task of improving warehouse performance for a Western Canadian Industrial Distribution Center. In this article, he tells you how he drove performance improvements on a tight budget.

A “Warehouse on Wheels” — Watch video of demountable containers that allow a DC to load multiple demountable containers on one trailer chassis at night, long-haul them to a regional market on semi trailers, then demount as a low-cost alternative to a regional DC or cross-dock.

Sample battery management reports — The EBatt battery management systems use software designed to allow managers to track and improve the efficiency of battery-operated vehicles, including battery-powered forklifts, pallet jacks, high-lifts, and other inventory handling equipment. Download samples of the various reports to learn more about these systems.

March 2009

Directory of dock scheduling software providers — Looking for a provider of stand-alone dock scheduling software? This directory of vendors can help you choose the one that best meets your needs.

“Consultant in a can” — Hempstead Consulting has developed a cost comparison tool designed to let you compare loaded carrier offers. View a sample of the spreadsheet here.

February 2009

Open Source WMS — Want to learn more about open source WMS? Software provider Compiere offers this description of its Compiere Warehouse Management system, built on an open source platform.

How much do you know about sleep? — Use the National Sleep Foundation’s interactive tools and quizzes to assess your own satisfaction with sleep, test your sleep IQ, and educate your employees about the importance of sleep.

January 2009

Receiving Operations and Docks — Looking for ways to improve receiving? This paper from CATTAN Services Group offers information on registering inbound information, analyzing dock requirements, sorting, staging, inspecting, and more. Also included is a template to use as a warehouse inbound shipping register.

Logistics Cost and Service Database — Download a copy of Establish, Inc.’s 2008 Logistics Cost and Service Database presentation. Online registration required.