The Problem: Legacy Racks Are Quietly Killing Operational Efficiency
Manufacturers are under constant pressure to increase output, reduce labor,
and maximize every inch of space—yet many still rely on the same inefficient WIP carts and traditional racking systems they’ve used for decades. These outdated solutions silently eat away at operational performance:
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Bulky carts take up valuable floor space.
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Limited part density means more trips, more racks, more bottlenecks.
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Dead air space goes unused, even as facilities run out of room.
In high-volume environments, these inefficiencies aren't just minor annoyances—they translate into hundreds of thousands (or even millions) of dollars in avoidable costs.
The Ripple Effects: Waste That Multiplies Across Your Operation
When storage systems don’t scale with production goals, the consequences ripple through your plant:
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Labor costs spike as handlers make more trips to deliver fewer parts.
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Production lines stall due to limited access to inventory.
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Facility expansion plans emerge—not because of growth, but because of poor space utilization.
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Freight costs balloon, as trucks leave half full.
One customer eliminated 172 standard racks and saved over 1,100 sq. ft. of floor space—on just a single program—after switching to the RZR Rack.
The Category Creation: RZR & FLX Rack — A New Class of Material Handling
The RZR Rack isn’t just an upgraded cart—it’s a category-defining innovation that flips traditional thinking on its head.
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Vertically expandable: Stores up to 60% more parts in the same footprint.
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Cuts floor space use by up to 40%: Room for new lines without expanding your building.
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Boosts transport efficiency: Fewer racks, fuller trucks, lower freight costs.
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Reduces handling: Fewer trips. Less downtime. More uptime.
And it’s not one-size-fits-all. Whether you choose the patented RZR Rack or FLX Rack, both offer unmatched flexibility—with options for custom cell sizes, footprints, ESD protection, Class A-friendly materials, & towing packages.
In one scale-up scenario, switching to RZR Racks across multiple programs was projected to save $8 million over 10 years.
This is not just a new rack—it’s a smarter, scalable system that reclaims your space, cuts waste, and transforms your floor layout from reactive to revenue-generating.
Ready to Work Smarter With the Space You Already Have?
If you’re running out of room, stuck with high labor costs, or just tired of doing more with less—maybe it’s time to rethink the racks.
Start a conversation with Diverse Global about creating a custom solution for your specific workflow. We’ll help you reimagine what your plant floor can do—without costly construction, chaos, or compromise.
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