Toyota Tsusho UK Ltd.

Toyota Tsusho UK Ltd.

To accommodate a new contract, top global automotive logistics specialist, Toyota Tsusho UK Ltd (TTUK) needed to undertake a major reorganisation of their Castle Donington warehouse.

We worked closely with TTUK to formulate a 2 phase plan which would integrate the new business whilst minimising the impact on existing contracts. An additional consideration was trying to redeploy existing equipment that had been acquired over the years within the final scheme.

Phase 1 involved dismantling existing racking to provide clear areas for floor picking and to allow installation of 840 locations of new racking, specific to the new contract. This allowed some new product to come into the warehouse whilst the existing racking, with some modifications, could later to be integrated into Phase 2 of the installation.

Phase 2 required 250 locations of customised drive in racking with integral rail mounted and floor mounted stops and pallet centring guides, to store unique steel pallet boxes to the clients’ requirements. 700 locations of new pallet racking specific to the new contract were installed and 1,450 locations of existing racking of which,1080 locations needed extending in height to suit the new requirement were redeployed.

The contract included relocating existing, and providing new barriers to fit in the cross aisles, fitting new and replacement load safety notices and fitting new and existing pallet safety mesh to the rear of single faced racks

All conventional pallet racking is fitted with pallet backstops and is decked in either steel mesh or open boarded timber decks. Tubular mounts to take location signage for the floor level picking locations were suspended from the roof purlins at 4,000 mm above ground level.

Our installation team liaised closely with TTUK operational staff during the contract to ensure minimal disruption to the warehouse and the project was handed over on time and within budget.

  • "IAW Logistics have been a pleasure to deal with throughout. I would highly recommend them."

  • "IAW Logistics helped me make the most of my space, were reliable and just made things easy."