Komatsu, a specialist in earth-moving equipment, partnered with BHD to implement specialised storage solutions in its new fulfilment centre in Melbourne.
Komatsu, a leader in earth-moving equipment, partnered with BHD to implement specialised storage solutions in its new fulfilment centre in Melbourne.
Komatsu’s Melbourne project serves as its first fulfilment centre, which was built to enhance customer service specifically for its construction and utility clients.
The centre is designed for efficient, quick picking, high consolidation – combining multiple orders into a single shipment – and next-day delivery.
Given Komatsu’s role as a manufacturer and distributor of large, heavy earth-moving equipment, robust and reliable storage solutions were essential to support operations at the new centre.
This is where David Seale, QLD State Manager from BHD Storage Solutions came in.
As an Australian company specialising in storage systems, BHD offers a range of products and services designed to optimise warehouse and distribution centre efficiency.
Komatsu engaged BHD to design and install racking systems tailored to the needs of its Melbourne fulfilment centre.
Hennie Van Der Merwe, General Manager of Warehousing, Komatsu, explained that there was some initial back-and-forth during the project, as BHD familiarised themselves with Komatsu’s commodities and requirements.
“We initially approached them with what we thought we needed and asked for a quote,” says Hennie.
“They would then review and come back with recommendations, explaining if any adjustments were necessary to meet local standards.
“Being an international company, our initial designs aren’t always aligned with Australian standards, but BHD guided us through those requirements.”
Hennie explained that, due to its global experience, Komatsu had specific feature requests for its racking, such as push-through bars and fire-retardant flues.
All of which, BHD was able to facilitate.
“BHD was incredibly helpful with these customisations, even facilitating local fabrications to meet fire safety requirements,” Hennie says.
“Their team didn’t just provide solutions; they worked closely with us throughout the process.”
The racks
Komatsu manages an inventory of 35,000 unique stock keeping units in its Melbourne FC to support its customers.
To store this range, seven specialised racking systems were designed and installed by BHD to meet the demands of Komatsu’s varied products.
“This includes extra-large, oversized racks, standard pallet racks, and specialised configurations for delicate items like glass,” says Hennie.
“Even small-scale racks, akin to those suited for office use, are custom-engineered and backed by independent engineering approvals to ensure compliance and safety across all configurations.”
To ensure safety and reliability, Komatsu commissioned an independent engineering assessment after installation to confirm that all racking met the necessary standards.
“Komatsu’s racking system complies fully with all industry standards and includes a range of configurations designed to accommodate its extensive variety of parts,” explained Hennie.
Other racks included a mobile racking system supporting up to 4,000 kg, which is used to store motors, gearboxes, and tracks stacked four-high, optimising floor space for non-uniform, heavy items.
“They showed us a mobile racking system at their Melbourne warehouse while we were reviewing designs for our Brisbane facility,” says Hennie.
“I was on my way back to Perth but ended up diverting to Melbourne to inspect the system firsthand.
“After seeing it, I was convinced, and we ended up purchasing it.”
This system is an eight-metre-high compact rack capable of holding 15 tonnes per bay.
These racks allow for the storage of large materials, accommodating heavy-duty items such as cooling equipment, engines, transmissions, and even rolls of track links.
“We stock these track links in bundles, similar to how you’d store tyres, for our excavators,” says Hennie.
“Each bundle weighs four to five tonnes, so we place them on this rack, open the system to access the materials we need, and then close it up when finished.”
Hennie explained that the mobile rack is a much faster pick system; while it may take about a minute to open-up, that’s minimal compared to block stacking, where finding a part can take up to three hours.
With block stacking, after retrieving a part, everything must be put back, risking lost inventory and complicating inventory control.
“Everyone who visits comments on it – they’ve seen similar racks before, but never on this scale,” says Hennie.
“Many leave saying they’ll install one themselves because they recognise the value it provides in terms of storage density, inventory control, and safety.
“With this system, items aren’t precariously stacked but securely organised on racks, which greatly improves both accessibility and safety.”
Hennie explained that Komatsu is now considering installing one of these mobile racks in some of its warehouses in Japan.
Apart from the mobile rack, the Melbourne FC also features a pallet racking system up to 10,000 mm high, with six distinct designs for different product shapes and weights.
Additional storage systems include 9,000 mm cantilever racks, hose racks, longspan racks, large parts racks, and CLS racks, enabling Komatsu to organise and access its wide inventory effectively.
Enabling Komatsu’s mission
Hennie explained that BHD’s racking solutions are empowering Komatsu’s Melbourne fulfilment centre to
deliver faster, more efficient, and customer-focused service by enabling high-density storage, streamlined picking, and secure handling of heavy-duty parts.
The fulfilment centre streamlines direct customer orders by consolidating multi-item purchases into a single, efficient delivery, bypassing traditional distribution channels to reduce costs and improve delivery speed.
“One of the main benefits we offer is order consolidation,” says Hennie.
“For instance, if a customer places a large, multi-item order, we ensure that all parts are packed and delivered in a single box and on a single day.
“This is crucial in industries like earthmoving, where customers need all parts at once for timely servicing.”
Ultimately, with BHD’s solutions, Komatsu’s Melbourne fulfilment centre is better equipped to meet customer needs swiftly and reliably.
Reflecting on the partnership, Hennie described the collaboration with BHD as a positive experience.
“We receive a very personal service from David Seale and his team,” he said.
Hennie credits BHD for its honest feedback, sometimes advising against a plan if it’s unsafe, or suggesting alternatives they’ve implemented elsewhere that might work better for Komatsu
“They truly put us as the customer first, understanding our needs and going above and beyond to take care of us,” he said.
“I consider them advisors or consultants; if I have a unique idea or design, I can call them for their input.
“It’s a solid partnership, and I’d say that’s the best way to describe our relationship.”
For more information on BHD Storage, click here.