Development of an Innovative Rack System for Modern Inventory Management

Abstract

Efficient inventory management is fundamental for modern businesses, requiring innovative storage solutions that enhance organization, accessibility, and space utilization. This study presents an alternative rack system designed to enhance warehouse efficiency while adapting to changing inventory demands. The system features modular configurations, durable yet lightweight materials, and ergonomic designs to support diverse storage needs. By maximizing space efficiency and optimizing load distribution, the design lowers operational costs and improves workflow. A comparative analysis with traditional racking systems highlights the advantages of the new design in flexibility, adaptability, and ease of use, aligning with modern logistics requirements. The study evaluates an industrial rack under a 1200-kg load using finite element analysis (FEA) and fatigue analysis, proposing structural enhancements. Quality Function Deployment (QFD) ensures alignment with customer needs. Static analysis identified critical high-stress and deformation points at the column-beam connection, with a maximum stress of 1.1 × 10⁹ N/m² and deformation of 10.8 mm. Increasing beam thickness reduced stress and deformation. Fatigue analysis showed an increase in life cycle from 600 to 900 cycles at critical points. Despite improvements, some high-stress areas still exceed material yield strength, indicating the need for stronger materials to ensure safe load-bearing capacity.