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Unit 4: Design of Storage and Handling Facilities - Coggle Diagram
Unit 4: Design of Storage and Handling Facilities
Initial Requirements
the company needs to have an outline of the original design and layout, customer requirements & design documented to facilitate change in the company's facilities.
two aspects determine initial requirements:
the facility(Storage and equipment), which the customer needs, can be easily accessible within the facilities. Match range of products & practices that are required by products offered to customers
PPC(Product Process Category), is a product or stock stored in a similar manner and requires the same handling (i.e. meat and ice cream stored in a cold area)
PPC requires different processes & areas i.e. Different temp zones
Multiple PPCs start to restrain the possible stored goods
Growth forecast for the facility,
most last over 10 years,
if it's too small leads to inflexibility for growth
Forecast future needs for each PPC
forecasting requirements are more important than the expected facilities
must be open and flexible for plans for the future
Sizing the warehouse
The warehouse is part of the supply chain & integrates inbound & outbound logistics transport
needs to cater to inbound/outbound logs transport
the building should take up 40-50% of the land leaving the rest for transport.
Needs to be cost-effective, with the floor and roof accounting for 80% of the warehouse cost
Expand storage vertically(storage in racks)
Other factors affecting the size of a warehouse:
Customer service levels
Size of market(s) served
number of products marketed
Size of the products
inventory turnover
aisle requirements
Operations & Warehouse Management Systems: necessary to define the principles of operations & capabilities of WMS
3 principles of operations
Method of receiving goods; partial receipt of loads reduces the size of receiving goods
The use and control of equipment in the warehouse; need appropriate equipment
Picking capabilities, items must be picked and replenished
Every step of operations requires equipment or storage/rest areas
Design Process
Assumptions
the number of PPCs, their requirements, and growth forecast are determined then the design can be realized in detail
Detailed design focus on the space and the capabilities required for handling each PPC
the design must be centered around operational processes of storage, receiving and put-away, order and picking, and dispatch
Process
Considerate the storage operational flows, receiving & dispatch in an iterative manner
Define the following for each PPC
Storage requirements
handling and moving areas
assembly areas for transport
receiving requirements
Combine requirements of PPCs(efficient & cost-effective)
which areas are unique to the PPC
Which areas can be combined in terms of space and accessibility (reaching for a summer blanket behind several winter blankets)
periods if operations
Storage
Basic modes:
Block stacking
racking
drive-in
mobile racking
Storage density is important(goods per meters squared), and racks should be easily accessible
the equipment used in to move pallets to and from rack slots determines aisle width (i.e. standard aisles stackers require an aisle size of 2,8m)
whereas a narrow aisle stacker requires 1,5m and is more costly to use than a reach truck
Outer space requirement for movement from aisle to aisle
Design Principle:
Storage density is directly dependent on the width of the aisles and the height of the racks.
the higher the racks or the smaller the aisle, the greater the density
Receiving
Size of the largest truck determines the design of receiving bay
2 important issues
ID the quantity and quality of goods,
record receipts in the warehouse
the size of the largest load = size of the load receipt(received) is used to determine the quantity and quality of the goods
Partial receipt before storage, reduces the size for receiving area(requires total load)
Design Principle:
design for current limitations, while identifying the potential for improvement
Pick area
Pick an area:
Items picked from storage or pick face(the location where orders that require less than full pallets are taken or picked, made for easier access such as the ground level),
if the truck takes the pallet to the dispatch area = no additional space
if the reach truck moves the pallet from the upper reserves to the pick face there is additional space
if processes are inefficient due to the selection or picking process, the picked pallet is moved to the handover area(via reach truck and pallet truck) and then moved to the dispatch area
Dispatch Area:
Quick transfer to create a truckload
Goods get picked from different parts of the warehouse various items in one area and different sections into one pallet
Partially full pallets from various areas of whose then created into one pallet
Consolidation of destinations
Assembly bay approx 10% bigger than the area covered by the largest truckload
Size is determined by the length of the lane of pallets in each bay, determined by the truck's largest capacity and 2 lanes of pallets, where each pallet lanes are half the length of the pallets form the largest transport size,
the number of routes of delivery at a time determines the number of bays
Movement Zones are defined to cater to all movements that will occur reflecting
Serve a number of PPC areas
that will use it concurrently(defined by periods of use)
Other requirements