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Chapter 10Warehouse LayoutLaying out a warehouse is like putting
together a jigsaw puzzle all the pieces have to be defined &
assembled
Defining the pieces is the purpose of: benchmarking, profiling,
simplification, computerizing, and mechanizing the warehouse
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Chapter 10Warehouse Layout5-STEP METHODOLOGY FOR WAREHOUSE
LAYOUT
Required Inputs: warehouse activity profile performance goals
for whse operations definition & configuration of warehouse
processes configuration of material handling & storage
systems
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Chapter 10Warehouse LayoutSTEP 1: SPACE REQUIREMENTS
PLANNING(determine overall space requirements)
Compute & Summarize Space requirements for each process:
ProcessFloor Space (sq ft)NotesReceiving Staging30,000Assume 80%
utilizationPallet Storage120,000@ peak inventoryCase
Picking25,000Broken Case Picking15,000
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Chapter 10Warehouse LayoutSTEP 1: SPACE REQUIREMENTS
PLANNING(determine overall space requirements)
Compute & Summarize Space requirements (continued):
ProcessFloor Space (sq
ft)NotesPackaging/Unitizing15,000Customizing20,000Assume 20% growth
in VASAccumulation/Sortation30,000Shipping staging30,000
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Chapter 10Warehouse LayoutSTEP 1: SPACE REQUIREMENTS
PLANNING(determine overall space requirements)
ProcessFloor Space (sq ft)NotesCross Docking15,000Warehouse
Offices15,000Restrooms5,000Shipping
staging30,000Subtotal320,000Interactive aisle64,000@ 20% of
subtotalTOTAL384,000
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Chapter 10Warehouse LayoutMost difficult decision is what
portion of peak storage requirement to accommodate. if duration is
short i.e.; ratio of Peak:Average is high Temporary space (outside
the warehouse) should be considered if the duration is long i.e.;
ratio of Peak:Average is low Warehouse should be sized very near
peak requirements
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Chapter 10Warehouse LayoutAnother important consideration:
Portion of warehouse locations that will be occupied
As utilization reaches 85 90% -- productivity and safety decline
dramatically
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Chapter 10Warehouse Layout2nd Step Material Flow
PlanningU-shaped Straight Thru Modular U-shaped Flow:
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Chapter 10Warehouse Layout U-Shaped Flow Advantages:Excellent
dock utilizationFacilitates cross-dockingExcellent fork truck
utilizationEnables 3 direction expansionExcellent securityIs the
benchmark for flow analysis
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Chapter 10Warehouse LayoutStraightThru Flow
RCVGSTORSELECTSHIP
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Chapter 10Warehouse LayoutStraightThru Flow
Lends itself to pure CROSS-DOCKINGwhen rcvg time & shpg
times coincide
Disadvantage: difficult to use ABC storage & dual command
trips
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Chapter 10Warehouse LayoutMODULAR-SPINE DESIGN
Good for large scale operations where operations are so large
they merit stand-alone, uniquely designed buildingsl.E.: a low-bay
air conditioned building for customized operations such as
monogramming, pricing, & marking;Plus a rack supported building
for a unit-load AS/RS; or a low-bay shipping building equipped with
high speed sortation equipment.
Good approach for grocery distributors (modules are dedicated to
specific order flows and/or item popularity designations.
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Chapter 10Warehouse LayoutMULTI-STORY LAYOUT
Employed where land is scarce: like Japan or Europe least
desirable of layout designs significant material handling
challenges bottleneck form in the flow
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Chapter 10Warehouse LayoutADJACENT PLANNING: ie:
Receiving & Reserve StorageCross-docking & ShippingCase
Picking & Pallet StorageCase Picking & Broken Case
PickingPicking & CustomizationCustomization & Unitizing
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Chapter 10Warehouse LayoutWarehouse Activity Relationship
Chart:
Supervision Safety Material Flow Work Flow Material control
Equipment Proximity Shared Space Employee Health &
SafetySecurityAbsolutely necessaryEspecially
ImportantImportantOrdinary ClosenessUnimportantX. Undesirable
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Chapter 10Warehouse LayoutPROCESS LOCATION:High storage
requirements use high bay areas &Labor intensive processes go
in low bay space:ReceivingBroken case pickingCustomizationReturns
ProcessingHigh bays can be mezzanined to create multiple low-bay
processes on the same foot print.
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Chapter 10Warehouse LayoutEXPANSION & CONTRACTION
PLANSRequirements change &Larger & smallerFaster &
slowerMore & less varietyTaller & shorterMore & fewer
peopleMore & less technologyThis requires careful configuration
layout to include expansion & contraction plans for each
warehouse area