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Outline

Outline. putaway pallet storage and retrieval case retrieval project. Operations in Warehouses. receiving prepackaging (optional) putaway storage order picking packaging and/or pricing (optional) sorting and/or accumulation unitizing and shipping. Putaway Principles

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Outline

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  1. Outline • putaway • pallet storage and retrieval • case retrieval • project

  2. Operations in Warehouses • receiving • prepackaging (optional) • putaway • storage • order picking • packaging and/or pricing (optional) • sorting and/or accumulation • unitizing and shipping

  3. Putaway Principles Putaway: The logistics process in a warehouse to put an incoming load after receiving to its final storage location

  4. Points to Discuss • putaway • touch reduction, distance reduction, efficiency improvement • pallet storage and retrieval • effect of rack type • effect of layout • factors to select • pallet storage equipment • pallet retrieval equipment • pallet retrieval

  5. Putaway Principles • primary objective: touch reduction and process streamlining • touch reduction: in increasing number of touches permanent storage primary picking locations direct shipping cross-docking marshalling area

  6. Distance Reduction in Putaway • how to reduce travel distance? • batched and sequenced putaway • interleaving and continuous moves

  7. Efficiency Improvement • directed putaway • using WMS to direct storage locations • benefits: to maximize storage location utilization, product rotation, retrieval productivity

  8. Storage System • classification by size • pallets, boxes, small items • two types of equipment • storage and retrieval

  9. Pallet Storage and Retrieval

  10. Pallet Storage System • storage racks • Floor Storage, Stacking Frames, Single-Deep, Double-Deep, Drive-in Rack, Drive Thru, Flow Rack, Push Back, Mobile Rack, Cantilever • retrieval equipment • Counter-balance, Straddle, Straddle Reach, Side-loader, Turret, Hybrid, AS/RS

  11. Effect of Rack Type and Layout • characteristics varying with rack type • example: single-deep versus double-deep • a venue of 109 slots with the door at the middle of the 10-slot side • aisle of one slot wide • which one is better, single- or double-deep? • statistics • utilization of area for: • 33 different types of pallets • 49 different types of pallets

  12. Pallet Systems: Block Stacking • factors to consider • safe limits, load stackability, load weights, pallet conditions, floor loading restrictions, weather, vehicle life, height capacity, crushability of the loads, building clear height

  13. Factors to Select the Pallet Storage Equipment • cost per position, position storage density, load access, throughput capacity, inventory & location control, FIFO maintenance, ability for variable load, ease of installation

  14. Floor Storage Stacking Frames Single-Deep Double-Deep Drive-in Rack Drive Thru Flow Rack Push Back Mobile Rack Can-tilever cost per position position storage den. load access F F A C B B B A F A throughput capacity B D B C C C A C F C inv. & location cont. F F A C D D C C D B FIFO maintenance F F A C D D A C C A ability for variable load A D C C D D F C C B ease of installation A A C C C C F C F B Pallet Storage Selection n/a $50 $40 $50 $65 $65 $200 $150 $250 $80 A B D C B B B B A B A: excellent; B: above average; C: average; D: below average; F: failure

  15. Floor Storage Stacking Frames Single-Deep Double-Deep Drive-in Rack Drive Thru Flow Rack Push Back Mobile Rack Can-tilever cost per position position storage den. load access throughput capacity inv. & location cont. FIFO maintenance ability for variable load ease of installation Pallet Storage Selection A: excellent; B: above average; C: average; D: below average; F: failure

  16. Pallet Flow Lanes Off-Site Floor Storage Double Deep Rack Push Back Rack Pallets On Hand Mobile Storage Single-Deep Rack Popularity Pallet Storage and Economic Analysis 11-12 1

  17. Factors to Select Pallet Retrieval Equipment • vehicle cost, life height capacity, aisle width, weight capacity, life speed, travel speed

  18. Counter- balance Straddle Straddle Reach Side-loader Turret Hybrid AS/RS Vehicle Cost $30K $ 35K $ 40K $ 75K $ 95K $125K $200K Life height capacity 22 ft 21 ft 30 ft 30 ft 40 ft 50 ft 75 ft Aisle width 10 – 12 ft 7 – 9 ft 6 – 8 ft 5 – 7 ft 5 – 7 ft 5 ft 4.5 ft Weight capacity 2 - 10 k 2 - 6 k 2 - 5 k 2 - 10 k 3 - 4 k 2 - 4 k 2 - 5 k Lift speed 80 pfm 60 pfm 50 pfm 50 pfm 75 pfm 60 pfm 200 pfm Travel speed 550 fpm 470 fpm 490 fpm 440 fpm 490 fpm 490 fpm 700 fpm Pallet Retrieval System Comparison

  19. Miscellaneous Issues • trade-off between aisle width & depth • honeycombing effect • co-existence of several systems in a warehouse • flow racks for fast moving goods & single-deep racks for slow moving goods

  20. Case Picking Systems

  21. Case Picking Systems • When is it unnecessary to discuss case storage systems? • incoming in pallet form

  22. Case Picking Systems • decisions • how to pick • palletizing or not • if so, where and how

  23. Year Rev. (NT$) 2007 2008 2009 2010 2011 Case Picking Systems 10 million • how to do it in • lativ • Amazon • the distribution center of Shiseido discussed before 100 million 370 million 1.5 billion > 4 billion

  24. Case Picking Systems • decisions: palletizing or not; if so, where and how • three types • pick face palletizing system • downstream palletizing system • direct loading system (no palletization) • criteria • goods characteristics, costs, pick rates

  25. Pick Face Palletizing Systems • palletizing during picking • pallet jack picking • lift truck picking • pallet trains • order picker trucks • end-of-aisle AS/RS • robotic case picking

  26. sort-ing Downstream Palletizing • two components, conveying to downstream and palletizing there • conveying downstream • pick-to-conveyor • case sorting systems • pick-car systems • automated case dispensing • tier (or layer) picking

  27. Downstream Palletizing • palletizing systems • manual palletizing • mechanical palletizing • robotic palletizing

  28. Picking Rates Initial Cost Pallet Jack 100-250 $1K to @10 K /vehicle Order Picker Truck 50-100 $30K/vehicle Pick to Roller 125-250 $1K/ft Pick to Belt 250-400 $200/ft + $2K/divert End-ofAisle AS/RS 200-300 $300K to $450K /aisle Auto Extract 500-800 $200K/unit = $130/lane Tier Picking 1,000-1,500 $150K/unit Case Picking System and Productivity Characteristics

  29. The Main Question • how to design a warehouse system • combination of equipment • layout

  30. Project • individual project • on a topic related to warehousing, warehouses, or both • discussing with Wan before finalizing the topic • three components: proposal, final presentation, and report

  31. Project • proposal: a 10-minute presentation, possibly including the following • introducing the problem • explaining its importance, relevance, and value • describing your procedure, method, expected results • final presentation: 10 minutes • report • (at least) 10 A4 pages • one a half line spacing • 12-ponit Times New Roman font • following the format of a technical paper

  32. Papers for the Second Half Semester • put in the general office

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