Case Study
Rustoleum — Hagerstown Project
Rustoleum is the leading manufacturer of premium consumer and industrial paint and coating products in the USA, with a dedicated production and warehousing facility in Hagerstown, Maryland & Attleboro.
Rustoleum is the leading manufacturer of premium consumer and industrial paint and coating products in the USA, with a dedicated production and warehousing facility in Hagerstown, Maryland & Attleboro.
Case Study
A facility not originally designed for such usage — re-engineered to grow for the next decade on the same footprint.
Project at a Glance
Rustoleum faced a number of immediate challenges — expanding production on the same footprint, additional raw-material throughput, and warehousing of completed production items on site. The increase in spray-can production, coupled with significant organic growth and a new product line, meant additional capacity requirements to support growth through the next decade.
Smart Partnering is the key to success. It starts with a shared vision between customer, consultant, and systems integrator — 1 Stop Material Handling was appointed the systems integrator of choice by Rustoleum, selected for its national reach, ability to up-scale, and a track record of delivering complex warehousing solutions on time and within budget.
The process evaluated warehousing-equipment alternatives to support growth, followed by racking-configuration alternatives to identify throughput requirements — brainstorming the supply chain, pallet-size configurations, and optimal growth solutions. After numerous design options, the final layout and racking configurations were achieved within the constraints of the existing building infrastructure.
Various options were investigated to design and equip the facility with a system that would accommodate the complex product flow between raw material, packaging items, and finished goods — in a facility not originally designed for such usage. Minimizing travel time, just-in-time raw-material stock levels, and faster inbound/outbound turnaround, while increasing floor utilization, were some of the accomplishments achieved.
It was determined that a narrow-aisle system combining push-back and selective rack — with maximum utilization of height — would result in a greater-than-50% increase in stored pallet positions relative to any alternative, yet with easy access to all pallets at all times.
Following a product-flow analysis, a secondary system of pallet-flow areas was designed and constructed to allow more up-time offloading packaging material and storing raw material closer to the relevant production areas, using existing equipment on site — increasing staging and marshalling areas and adding flexibility to the overall design.
The Smart Partnership between Rustoleum and 1 Stop Material Handling's team of project managers and senior management delivered a system specifically designed to the customer's actual on-site usage and requirements today, while making provision for future growth.
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A 50-foot-high, 25,000-pallet system — built in 90 days, and engineered to grow taller.
“Our company made the best investment this last year in hiring 1 Stop for our pallet racking. Working with Peter and Jennifer made it seamless, and the work was sound, professional, and on time. They’ll be our resource for all racking and warehouse needs going forward.”
