Very Narrow Aisles (VNAs)
Cycle Counting

Very Narrow Aisles (VNAs) have become a prevalent warehouse design strategy for maximizing storage capacity and efficiency. VNAs refer to aisles that are significantly narrower than traditional warehouse aisles, often just wide enough to support the width of a typical  wire-guided order picker/ turret truck(42-48”).  By narrowing the aisles, more shelf space becomes available for storing goods vertically. This vertical storage maximization is particularly beneficial for warehouses with limited floor space.  While this approach helps expand storage space for a warehouse it also presents a challenge when it comes to cycle counting due to not just limited space constraints, but also the increased cubic density of storage, which requires additional manpower.

The improved space utilization of VNA comes with a cost and often that includes limited space to support cycle counting automation techniques, including:

• Warehouse Drones – while warehouse drones come with promises for automation and efficiency benefits, their use is limited in VNAs due to the narrow spaces that restrict their maneuverability and pose a safety concern. On top of that, drones need to maintain a distance from the racking so that they can capture the full pallet location in one frame, however this is not possible in VNAs that are themselves 5ft wide as the drone gets too close to the other side of the aisle. High density case storage locations in VNAs make it even more challenging for drones as the case labels are more difficult to read and the drone must make exponentially higher number of stops to capture everything in a shelf in a short flight time. Before considering a drone for VNA cycle counting, talk to a drone provider first so they can explain the limitations (read this post to learn more about the challenges of warehouse drones).
• Manned Order Picker/Cherry Pickers – Warehouses commonly conduct cycle-counting using handheld RF scanners. This poses a safety risk as an operator has to scan boxes 30 feet high up on a cherry picker and lean into the racking to scan boxes. Warehouse associates are sometimes pushed to meet their aggressive cycle counting goals and may employ some risky techniques to reach out and scan as many items in one stop.  Additionally, this form of cycle counting is very slow needing warehouses to hire a team of cycle counters and train them in this high-churn job.