Industry: Commercial Truck Components
Project Type: Full Warehouse Fit-Out
Location: Auckland, New Zealand
Who Are Hendricskon asia pacific
Client Overview
Hendrickson Asia Pacific is a leading manufacturer of commercial truck suspension systems and components, serving markets across the Asia Pacific region. With more than 50 years of industry experience, their product portfolio includes axles, air and mechanical suspension systems, tyre pressure control systems, and auxiliary lift axle systems.
To support ongoing growth and meet rising operational demands, Hendrickson recently developed a purpose-built warehouse facility in Auckland, designed to centralise operations and improve logistical efficiency. With scalability and functionality at the core of their requirements, they turned to Storepro to deliver a complete warehouse fit-out that aligned with their high standards for performance and reliability.
Project Challenges
As part of their transition into a new facility, Hendrickson needed to completely rack out their warehouse with a storage system that could support both current stock profiles and future inventory expansion. The challenges were multifaceted:
1. Strict Timeframe to Meet Operational Deadlines
Hendrickson had a fixed go-live date for the new facility, meaning all infrastructure including the racking, safety systems, and small-parts picking areas, needed to be fully operational within a compressed timeline. Any delays could have disrupted supply chain activities and impacted customer delivery schedules.
2. Coordination With Multiple Trades and Site Activities
As the warehouse was still under final stages of construction and setup, the site was busy with various contractors like electricians and flooring teams to security system installers. This created a highly dynamic work environment, where access was limited and timing was critical. We had to work within a shifting schedule while coordinating effectively with all stakeholders to avoid bottlenecks.
3. Product Diversity and Storage Complexity
Hendrickson’s product range includes large, heavy, and often non-standard truck components (such as axles and suspension assemblies) that require tailored racking systems for safe and efficient storage. Simultaneously, they also needed a system for storing and picking a high volume of small parts, which added another layer of complexity to the design.
4. Turnkey Responsibility and Regulatory Compliance
We weren’t just installing racking, we were also responsible for delivering a complete, end-to-end warehouse fit-out, including building consent approval, safety barrier installation, and the provision of over 1,000 tote bins for small-parts storage. Every component had to meet New Zealand compliance and safety regulations, which required meticulous planning and documentation.
How Storepro Overcame the Challenges
We successfully managed the complex warehouse fit-out by providing end-to-end project oversight, acting as a single point of contact to reduce coordination issues. Our agile project management ensured smooth scheduling alongside other on-site trades, while their tailored racking design accommodated both large and small parts efficiently. By handling everything from building consent to safety installations, we delivered a fully compliant, scalable, and operationally effective warehouse, on time and within budget.
OUR SOLUTION
The Storepro Solution
Storepro’s team worked closely with Hendrickson to design and implement a customised warehouse fit-out that balanced structural integrity, operational efficiency, and future-proofing.
A bespoke racking system was proposed to accommodate Hendrickson’s diverse product mix, including truck axles of varying lengths and pallets stacked with multiple units.
Integrated pick faces using 1200 Lamsons bins/tote boxes were incorporated to streamline the picking of smaller components, dramatically improving stock visibility and retrieval efficiency.
The racking layout was engineered to maximise vertical and horizontal space, eliminate wasted air gaps, and support better inventory flow.
Safety and compliance were integral to the design, with Storepro also managing the supply and installation of fork-safe barriers and overseeing the building consent process to meet all regulatory requirements.
SOLUTION & OUTCOME
Work Carried Out
We delivered a comprehensive warehouse storage solution tailored to Hendrickson’s operational and safety needs, managing the entire fit-out from structural design to final installation and compliance.
- Racking System Installation: Installed 70 bays of industrial-grade racking, strategically configured to optimise both floor space and vertical clearance. The racking was designed to accommodate over 800 pallet spaces, significantly increasing storage density while maintaining accessibility. Configurations were adjusted to support the safe and efficient storage of Hendrickson’s oversized products, such as truck axles and suspension components, which often have non-standard dimensions and weight distributions.
- Pick Face & Small Parts Storage: Integrated 1,200 Lamsons bins (tote boxes) into the racking system to create clearly defined pick faces for small parts and components. These bins were organised to improve inventory visibility, reduce mispicks, and streamline the picking process, essential for parts that are accessed frequently or shipped in small quantities.
- Safety Infrastructure: Installed 23 linear metres of fork-safe safety barriers, designed to protect high-traffic racking zones from impact by forklifts or manual handling equipment. Safety compliance was prioritised throughout the project, with protective infrastructure added to ensure adherence to New Zealand workplace health and safety standards.
- Building Consent and Compliance: Storepro managed the full Building Consent process, including site assessments, layout documentation, and engineering sign-off. All materials and installations met New Zealand regulatory standards for industrial warehouse environments, ensuring long-term structural integrity and compliance.
- Project Management and Delivery: Installation was completed in under two weeks, despite the presence of multiple trades on-site and a tight operational deadline.
Storepro’s team coordinated daily with other contractors and maintained clear communication with Hendrickson’s internal team to avoid delays and ensure the project remained on budget and on schedule.
The Outcome
The new warehouse setup has significantly improved Hendrickson’s operational efficiency and storage capacity:
- 60% increase in pallet capacity, eliminating floor stacking and making better use of vertical space.
- 1200 clearly defined pick faces have enhanced stock organisation, reduced picking times, and improved inventory accuracy.
- The layout has improved warehouse flow, enabling faster loading and unloading processes and reducing forklift congestion.
- The entire system is modular and scalable, giving Hendrickson the flexibility to expand or reconfigure storage as business needs evolve.
Thanks to their partnership with Storepro, Hendrickson now operates a fully optimised, compliance-ready warehouse built for efficiency, safety, and long-term growth.
“We had a great experience working with Richie and Storepro on our pallet racking project. Although our project had moments where they had to be patient, since our site was a purpose-built facility, they helped us at every opportunity to deliver the project. This is my second racking project with Storepro, and they have performed well on both for me. I would recommend working with Richie if you’re after a reliable and professional approach to warehouse racking.”
Kurt McDonald
Business Process Improvement Specialist, Hendrickson Asia Pacific Pty Ltd
STORAGE SOLUTIONS PROVIDER
Why choose Storepro?
Tens of thousands of customers can’t be wrong. As the largest 100% NZ owned and operated business in our industry, at Storepro we bring a deep understanding of your warehousing needs, wants and goals.
We design, engineer and build all of our solutions right here in NZ. But we don’t just build warehouse racking – we build relationships too. We listen to your needs, develop bespoke solutions, and support you all the way.
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