LKQ (Euro Car Parts) – Destacking of tall stacks of totes

LKQ's (Euro Car Parts) distribution network uses standard sized totes containers, stacked five layers high on wheeled dollies to transport stock from distribution centres to branches.

Stacking the totes fiver layers high maximises vehicle fill and utilisation, however, a concern is that the top two layers of totes, each containing up to 25kg of goods, are above shoulder height. Under Health and Safety guidelines for manual handling, this increases the risk to colleagues when de-stacking the totes at branch.

The investment dramatically reduced the manual handling of parts and increased picking productivity and vehicle utilisation compared to historical use of roll cages.