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IENG 471 - Lecture 16

IENG 471 - Lecture 16. Warehouse Operations – Facility. Warehousing Terms. SKU – Stock Keeping Unit Product in (packaged) form for warehouse operations Value-Added A modification to the product to obtain business

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IENG 471 - Lecture 16

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  1. IENG 471 - Lecture 16 Warehouse Operations – Facility IENG 471 Facilities Planning

  2. Warehousing Terms • SKU – Stock Keeping Unit • Product in (packaged) form for warehouse operations • Value-Added • A modification to the product to obtain business (a product enhancementfrom the customer’s perspective or an enhancement to the customer’s experience in getting the item) • Cross-Docking • Transforming incoming product to outgoing product without moving the product to production or storage • Spotting • Locating and positioning a carrier vehicle within the loading / unloading areas of the facility • ASN – Advance Shipping Notice • Information about a shipment sent from the shipping firm to the receiving firm, directly through EDI (electronic data interchange) IENG 471 Facilities Planning

  3. Warehousing Metrics • Order-picking Improvement • Productivity Improvement • Space Utilization Improvement • Value-Added Improvement • Safety Improvement • Personnel & Equipment • Cargo • Most plants do not make their money in the warehouse… • For some, the warehouse IS the plant! • Distribution centers (Target, x-Mart; grocers; airports; …) • Shipping businesses (Fed Ex, UPS; shipping ports; movers; …) IENG 471 Facilities Planning

  4. Warehousing Functions • Receiving • Quality Inspection • Repackaging • Put-away • Storage • Order-picking (postponement) • Sortation & Accumulation • Packaging & Shipping • Cross-Docking • Replenishment IENG 471 Facilities Planning

  5. Receiving Operations • All or a subset of the following sequence: • Inbound delivery scheduling and information exchange • ASN verification and confirmation • Delivery arrival and spotting • Vehicle secured at the receiving dock • Seal inspection / breaking • Initial delivery inspection – accepted / refused • Merchandise unloaded (unitized or loose) • Unloaded material is staged for final inspection • Determination & disposition of carrier damage • Load storage & over-pack disposal activities IENG 471 Facilities Planning

  6. Shipping Operations • All or a subset of the following sequence: • Order accumulation & packing • Order staging for loading / labeling & out-going inspection / counting • Customer order & shipping release reconciliation • Spotting carrier to a dock • Securing carrier vehicle at dock • Loading vehicle • Dispatching the vehicle IENG 471 Facilities Planning

  7. Facility Accommodations for S & R • Carrier spotting areas • Staging & inspection areas • Dock levelers & locking devices • Loading / unloading areas • Palletizing / repackaging space • Information system access for ASN / EDI • Carrier personnel space IENG 471 Facilities Planning

  8. Shipping & Receiving Analysis • Analysis of requirements for: • What is to be received and shipped • Peak product volumes • Timing of peaks, and growth • How many docks to be planned • Carrier vehicle quantities • Timing of arrivals & departures • What kinds of dock equipment to be used • Carrier vehicle types and variants • Environmental conditions for loading / unloading • How much space is required for shipping and receiving activities • SKU container volumes • Shipping debris volumes • Material handling equipment space • Carrier vehicle dock access and spotting space • Carrier personnel space IENG 471 Facilities Planning

  9. SKU Analysis IENG 471 Facilities Planning

  10. Truck Access • Service roads should be at least 24 ft wide if two-directional, and at least 12 ft wide if the road is one-directional • Add at least 4 ft to the road width if gate openings are needed • Provide a 4 ft wide walk, physically removed from the road, if pedestrian traffic is required along service roads • Increase gate openings by 6 ft if pedestrians will pass through • Right angle intersections should have at least a 50 ft radius • Prefer counterclockwise traffic circulation because left turns are safer than right turns**(UPS study suggests right turns!) • Truck waiting areas should be designed to hold the maximum expected number of trucks, and should be located adjacent to the dock apron IENG 471 Facilities Planning

  11. 90o Apron Space • Aprons are space allotted for spotting a vehicle – maneuvering room to align with the dock IENG 471 Facilities Planning

  12. Angled Apron Space (Finger Docks) • Angled Aprons allow for access to tighter spaces IENG 471 Facilities Planning

  13. Material Handling Equipment Space • MHE Space Is in addition to staging, storage, dock, and personnel space; and allows for maneuvering the MHE vehicle … IENG 471 Facilities Planning

  14. Storage Space Analysis IENG 471 Facilities Planning

  15. Design of Warehousing Space • Similar to design of the rest of the facility: • Efficiency of space utilization should not detract from the function of the facility • Storage space may be allocated similar to production space • Pareto principal (80/20 Rule) • Group Technology applies • Information Systems improve picking operations IENG 471 Facilities Planning

  16. Questions & Issues IENG 471 Facilities Planning

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