Used Jungheinrich trucks are refurbished to the highest standards. Every machine is dismantled and all worn parts are replaced - including tyres and lift chains. The trucks are cleaned inside and out and repainted before being reassembled and safety tested.

"Because we refurbish our trucks to such a high standard, the operating costs of a used Jungheinrich truck will be similar to a new model, which means that our fully refurbished trucks will give many years of efficient and productive service," says Neil Warren, Jungheinrich UK Ltd's Used Equipment and Short Term Rental Director.

"Our aim is to help clients manage their forklift cost base effectively and we were able to demonstrate the benefits that switching a percentage of its fleet to used trucks would bring to First Line," Neil Warren adds.

As part of the consultation process on the project Jungheinrich were also able to offer some useful advice regarding the proposed use of racking at the new site.

First Line had initially planned to reuse much of the racking system from their original buildings within the new facility.

"Like any business, we strive to remain lean and had planned to recycle our racking," says Rob Currill.

He continues: "However, Jungheinrich's consultants were able to demonstrate that not only was our existing racking not fit for purpose, but that opting for a new system, would actually be less expensive than taking down, reconfiguring and erecting our old system within the new store.

"While some of the existing system has been reused on the goods-in consolidation area, we now have a purpose designed high bay storage cube produced from brand new racking."

First Line had planned to move in over the Easter period, but with favourable weather conditions allowing construction of the new site to be completed sooner than expected, Jungheinrich were able to deliver and install the re-used racking for the consolidation area and the new high-bay racking cube one month ahead of schedule. As a result of Jungheinrich's flexibility, First Line could start migrating stock from their existing stores to the new facility several weeks ahead of plan.

The finished design of the new store means that while orders for certain slow moving or bigger parts are picked and despatched directly from the bulk store, the majority of the products stored within it are transferred across the DC to replenish the shelves within the small parts storage area.

First Line's clients place orders either electronically (in 70 per cent of cases) using an EDI-based system or by telephone. Orders placed before 6pm can be supplied next day anywhere in the country.

Once an order is complete it is triple checked before being boxed and delivered to the goods out area where it is loaded onto First Line's parcel delivery partner's waiting trailer.

"It's a very simple system," says Rob Currill. "But it works well."

"Product management is key to our business. We have over 35,000 part numbers in our catalogue and we are currently running at 96 per cent availability. Our clients rely on us for next day delivery to ensure that they can offer the highest standards to their customers so an efficient storage and picking function is essential."