BM317 Lecture 3 :Warehouse Space and Layout Planning
Warehouse Space and Layout Planning
BM317 Warehousing and
Inventory Management
Lecture 3
1.
Ownership (rent, lease or build)2.
Size and number of warehouse3.
Where should warehouses be located?4.
How much capacity is required?5.
What type of warehousing layout is appropriate?Basic Warehousing Decisions
What is the one thing you always run out of
in a warehouse?
The answer is space....................
Warehouse Space Planning
1.
Determine what is to be accomplished2.
Determine how to accomplish it3.
Determine space allowances for each elementrequired to accomplish the activity
4.
Calculate the total space requirementWarehouse Space Planning
Two Major Activities Require
Space Planning
1.
Receiving and Shipping Activities2.
Storage ActivitiesSpace Planning for Receiving
and Shipping
The most important functions of a warehouse
take place on the receiving and shipping docks.
Unfortunately, these are also the most neglected
areas of the warehouse.
How then do we plan the space requirements for
shipping and receiving?
1.
Defining the materials received and shipped2.
Determining dock bay requirements3.
Dock bay configuration4.
Maneuvring allowances inside the warehouse5.
Buffer and Staging area requirements6.
Dock-related space requirementsMethodology of Space Planning
for Receiving and Shipping
An excellent tool – Receiving and Shipping Analysis
Chart (RSAC)
1. Defining the Materials Received
and Shipped
Columns 1-5: define what is to be received or shipped Column 6: size of shipment Column 7: when the receipts and shipments will occur Columns 8-9: list the types of carriers Columns 10-11: handling methods & time required for loading/unloadingDescription Type Capacity Size Weight Mode Specs Method Time, hr
1 2 3 4 5 6 7 8 9 10 11
Steel pipe
plug
Wooden
crate
3200 pcs 2ft x 2ft x
4ft
835 lb 12 crates Quarterly Truck 34ft x 8ft
x 7ft
Fork
truck
0.75
Aluminum
bar
Bundles 25 bars 12.5 in x
14in x 6ft
1625 lb bundles Monthly Openbed
truck
34ft x 8ft Crane 5
Material Handling
Size of
Shipment
(Unit Loads)
Frequency
of
Shipment
Unit Loads Transportation
Determining the requirements for the receiving and
shipping dock bays
How many dock bays are required?Frequency of activity
Carrier inter-arrival time and service time
Guessing
Waiting-line analysis
Simulation How should the dock bays be configured?
Types of vehicle at the dock bay
2. Determine Dock Requirements
90
O Dock3. Basic Dock Configuration
Dock
Truck
Dock
Truck
45
O Finger DockBerth width
Berth width
Apron
depth
Apron
depth
45O
90O Dock:
requires less width and more depth requires less inside warehouse space and more outsidespace than a finger dock
Space needed to enter and exit the carrier and totravel between the carrier and the receiving buffer
area or the shipping staging area
Area occupied by the dock leveling devices An aisle located between the back edge of theinside dock leveling device and the receiving buffer
area or the shipping staging area
Required width: 6-8 feet for manual handling and nonpoweredmaterial handling equipment and 8-12 fleet for
powered material handling equipment
4. Manoeuvring Allowances Inside
the Warehouse
The receiving buffer area serves as a depository for the materials unloaded from the carrier perform thorough check-in and inspection
The shipping staging area serves as an accumulation point for the merchandise that comprise a
shipment
perform packaging, unitizing or verifying the customer orderDetermining the amount of the buffer/staging area a matter of the degree of control over the dock area based on how much area is required during the surge periods Existing facilities – by analyzing historical shipping patterns New facilities – ask the anticipated suppliers and users & based on
the anticipated surges in activity
Aisle space within the buffer/staging area
5. Buffer & Staging Area Requirements
Access
aisle
Dock maneuvering area
Receiving and Shipping Area
Truck
Truck
Truck
Truck
Dock
levelers
Dock
levelers
Buffer / staging
area
Buffer / staging
area
Office Space Receiving hold area Trash disposal Empty pallet storage Truckers’ lounge6. Determine Dock-Related Space
Requirements
Space Planning for Storage Activities
1.
Defining materials to be stored2.
Choosing a storage philosophy :3.
Space requirements for alternative storagemethods
A useful tool – Storage Analysis Chart (SAC)
1. Defining the Materials to be Stored
Columns 1-5: define what material are to be stored Columns 6-8: how much is to be stored Columns 9-12 how the materials are to be storedDescription Type Capacity Size Weight Maximum Average Planned Method Specs Area,ft2
Ceiling
Height,ft
1 2 3 4 5 6 7 8 9 10 11 12
Steel pipe
plug
Wooden
crate
3200 pcs 2ft x 2ft x
4ft
835 lb 14 8 12 Pallet
rack
25ft x
10ft x 3ft
66 9
Aluminum
bar
Bundles 25 bars 12.5 in x
14in x 6ft
1625 lb 30 17 30 Storage
shelf
12ft x 2ft
x 8ft
24 8
Unit Loads Quantity of Unit Loads Stored Material Handling
2. Determine Storage Philosophy
1.
Fixed location storageeach individual SKU is always stored in a specific
location, and
no other SKU may be stored in that location, even
though that location may be empty
2.
Random location storageany SKU may be assigned to any available storage
location
3. Determine Alternative Storage
Method Space Requirements
1.
The space requirements are directly related tothe volume of material to be stored, and
2.
The use-of-space characteristics of thealternative
Aisle allowance
Honeycombing allowance
Aisle & Honeycombing Allowance
1.
Aisle allowance is the % of space occupied by aislesIt is necessary within a storage area to allow accessibility to
the material being stored
The amount of aisle allowance depends on
the storage method, which dictates the no. of aisles required, and
the material handling method, which dictates the size of aisles
2.
Honeycombing allowance is the % of storage space lostIt occurs whenever a storage location is only partially filled
with material and may occur horizontally and vertically
The unoccupied area within the storage location is
honeycombing space
Honeycombing Space
A B C Horizontal A B C
A B C honeycombing A B C
A B C B C
A B C C
A B C Vertical C
A B C honeycombing B C
A B C A B C
Ceiling Ceiling
Floor Floor
Wall
Aisle
Wall
Aisle
1.
To use space efficiently2.
To allow the most efficient material handling3.
To provide the most economical storage in relationto costs of equipment, use of space, damage to
material and handling labour
4.
To provide maximum flexibility in order to meetchanging storage and handling requirements
5.
To make the warehouse a model of goodhousekeeping
Objectives of a Warehouse Layout
Layout planning methodology consists of two steps:
Generate a series of warehouse layoutalternatives
Evaluate each alternative against specific criteriato identify the best warehouse layout
Layout Planning Methodology
1. Define the location of fixed obstacles
2. Define the location of the receiving
and shipping functions
3. Locate the storage areas and equipment,
including required aisles
4. Assign the material to be stored to the
storage locations
5. Repeat the process to generate other
alternatives
Generate Alternative Layouts
1.
Popularity Philosophy2.
Similarity Philosophy3.
Size Philosophy4.
Product Characteristics Philosophy5.
Space Utilization PhilosophyConservation of space
Limitations on use of space
Accessibility of material
Orderliness
Evaluate the Alternative Layouts
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Of course, you also need to resolve any safety issues in the warehouse. Doing so can reduce the risk of accidents; fire for example can cause severe damage and the risk can be high depending on the items stored. By keeping safety a priority, one can formulate a layout plan that can be efficient, productive, and safe.
Posted by: Duane Williams | February 12, 2012 at 02:06 AM