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Unit load Storage & Retrieval Handling Docking ID & Comm

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Lecture 03Equipments in Warehouse:

Oran Kittithreerapronchai1

1Department of Industrial Engineering, Chulalongkorn UniversityBangkok 10330 THAILAND

last updated: December 29, 2014

Warehouse v2.0: Equipments 1/ 39


Outline

...1 Unitizing equipment

...2 Storage & Retrieval equipments

...3 Material handling equipments

...4 Docking-related equipments

...5 Identification & communication equipment

source: General references [BH09, Mul94, Fra02]



Benefits of equipment

Reduce cost (labor + space)enhance space utilization (rack → vertical dimension, denser packing)allow for more efficient order-picking (WMS → zone picking )

Enhance responsivenessIncrease throughput of facility (A-frame → SKU density & automated transfer)

Maintain qualities of products & operationsprovide efficient ways for identification (e.g., bar code, RF terminal)provide safe & secure material handling (e.g., reach truck)establish & maintain a controlled environment (e.g., temperature control,access control)



Concept of unitizing equipment

Idea: standardizing SKUs → easy to move & collectWhere: supplier site, receiving & shipping areaIssues: installation cost, volume, size & shape (7Eleven tote, Lotus cool box)Example: pallet, wrapping machine



Pallet & co

Idea: creating unit load by std platformIssues: circulation, size, form



Comparison of pallet materials

Material Durability Repairable Env. Impact ApplicationWood med yes recyclable commonPressed Wood med yes recyclable printing, tiberFiberboard low no recyclable paper, garmentPlastic high no closed loop cement, automotiveMetal high depends closed loop grocery, food, military

Standard PalletsISO pallets 1000 mm × 1200 mm

US pallet 40 in × 48 in (1016 mm × 1219 mm) or 42 in × 48 inEuro pallet 800 mm × 600 mm & 800 mm × 1200 mm



Other pallets



Other type of unit load



Storage & retrieval equipment

Idea: cubic space saving & efficient retrievingWhere: storage & picking areaIssue: standardization, FIFO, safety, ergonomicExample: floor stack, selective rack (single deep & double deep), carrousel



Floor stack: No equipment

Idea: stack pallets up-heightPro: zero investment, multiple pallets per SKU, high inventory overCon: honeycombing problem, stabilityIssue: stack-ability, stack height, aisle width



Industrial rack



Single-deep rack

Idea: a pallet rack that has a single storage spacePro: each pallet is independently accessibleCon: too many aisles → inefficient space utilization



Double-deep rack

Idea: a pallet rack that has a double storage spaceImportant: Each lane dedicated to one SKU (one pallet or two pallets)Pro: Less aisle space required (upto 50% savings in aisle space)Con: More work and/or specialized equipment for retrieving



Drive-in & drive-through rack

Idea: forklift can drive in the structureImportant: ∃ two aisles → drive-through, ∃ inclined rollers → push-backPro: maximize space utilizationCon: accidents, inefficient of vertical dimension



Cantilever rack

Idea: structure with protruding beams to support itemsPro: suitable for irregular/long shaped productCon: strength, balancing, pallet >> carton/piece



Comparison of unit-load equipments

Block storage Selective Double deep CantileverInstalled (USD/unit load) − 150 150 200Footprint − large medium largeStorage density high low medium lowThroughput high high medium mediumSpace use very good fair good fairLoad accessibility poor excellent fair excellentRotation of loads LIFO FIFO LIFO FIFONumber of aisles few many medium manyUnit loads deep/opening 8-10 1 2 1Utilization factor 60% 85% 80% 85%Probability of damage high low low lowSecurity poor good good good

source: Malmborg, C. et al. 1998 [PMP+98]



Pallet flow rack

Idea: a pallet rack that always brings next palletImportant: separate picking & put-awayPro: high pick density, FIFOCon: space utilization, high cost



Gravity flow rack

Idea: a rack that always brings next case/carton (200+ picks/hr)Pro: high pick density, FIFOCon: space utilization, high cost



Bin shelve

Idea: storing cabinet for case/cartonPro: cheap,Con: single access, ID, low pick density, LIFO



Carousels

Idea: automatic storage/retriving equipment (100-200 pick/hr)Pro: no searching, securityCon: single access



A-frame

Idea: combine picking, storing & packing with automation (300+ pick/hr)Pro: high pick density for small & similar SKUs ready packCon: double handling, filling machine



Small storage item equipments



Material Handling Equipment

Idea: moving items/SKUsWhere: everywhereIssue: reach, automation, space footprint, congestionExample: hand truck, forklift, conveyor



Counter balance forklift truck

Idea: unit-load mover equipped with motor & hydriodicPro: very usefulCon: wide turn → wide aisle



Hand truck & pallet truck

Idea: manual/semi-auto equipment for moving pallet (no driving cab)Pro: small, cheapCon: more manual, fixed height (i.e., not apply for reversible pallet)



Very narrow aisle equipment (VNA)

Idea: storage or handling equipments for very narrow aisle (VNA)Pro: no or little turn, high space utilizationCon: very expensive, special building



Crane

Idea: handling equipments that moves in fixed pathsPro: flexible shape/sizeCon: restricted area, congestion with others



Others material handling equipment



Conveyor

What: manual/semi-auto equipment for moving pallet (no driving cab)Pro: no additional cost,Con: large moving huge std. size, fixed paths



Space requirement for popular equipments

Design SpecificationNo. Storage Handling Pallet Pallet Slot Aisle Avg.

($/pallet) ($/unit) Depth Height Width Width Utiliz.1 Floor ($0) Forklift ($22k) 6 3 1.35 3.6 0.302 Drive-In ($150) Reach ($28k) 6 5 1.35 3.6 0.903 Double Deep ($55) Deep Reach ($35k) 2 5 1.25 3.0 0.754 Push-Back ($155) Reach ($28k) 4 5 1.25 2.7 0.855 Selective ($50) Reach ($28k) 1 5 1.25 2.7 0.80

QuestionsCalculate area requirements for each option if a particular warehouse, on average, needs 3000 palletpositionsPropose a layout if the width and height of a storage area of this warehouse are 36m. and 20m.

source: Napolitano, M. et al. 2003 [NG94].



Dock-related equipment

Idea: making loading & unloading easierWhere: receiving & shippingIssue: weight, layout (blind spot)Example: dock door, dock leveler, staging area



Dock doors



Dock area



Identification equipment

Idea: speeding receiving & shippingWhere: receiving & shippingIssue: integration with systemExample: RFID, bar code reader, magnet



Bar code scanner & RF terminal



Equipments selection

Price: designed throughput, ROI, cycle timeMaterial: physical appearance, quantityLogistics: location, speed, distance, congestionRestriction: area, aisle width, congestion, power availability, door sizeSystem: policy location, ID system, simple procedure, worker, otherequipmentsMaintenance: spare part, training programOther: prone to accident, customer, industry standard



Useful information

Material HandlingMaterial Handling Taxonomy: http://www.mhia.org/industrygroups/cicmhe/resources/mhe_tax.htmMaterial Handling Pictures: https://www.cirrelt.ca/mhmultimediabank/

Warehouse ToursInteractive Tour: http://www.roodbergen.com/warehouse/Warehouse Science: http://www2.isye.gatech.edu/j̃jb/wh/sites/sites.html


http://www.mhia.org/industrygroups/cicmhe/resources/mhe_tax.htm

http://www.mhia.org/industrygroups/cicmhe/resources/mhe_tax.htm

https://www.cirrelt.ca/mhmultimediabank/

http://www.roodbergen.com/warehouse/

http://www2.isye.gatech.edu/~jjb/wh/sites/sites.html


Problems

1. Why does a single-deep rack accommodate FIFO & & FEFO policy, but notdouble deep rack?

2. Why floor stack is more suitable for a unit load fast-moving item thandouble-deep rack?

3. Compare similarities & differences of the following equipmentsselective rack & cantilever rackdrive-in rack & drive-through rack



Reference

[BH09] J. J. Bartholdi and S. T. Hackman.Warehouse & distribution science.Suply chain and logistics institute, Georgia institute of technology, 2009.

[Fra02] E. Frazelle.World-class warehousing and material handling.McGraw-Hill Professional, 2002.

[Mul94] D.E Mulcahy.Warehouse distribution and operations handbook.McGraw-Hill New York, 1994.

[NG94] M. Napolitano and JE Gross.The Time, Space & Cost Guide to Better Warehouse Design: A Hands-on Guide toHelp You Improve the Design and Operations of Your Warehouse Or DistributionCenter.Distribution Center Management, 1994.

[PMP+98] Brett A Peters, Charles Malmborg, Glenn Petrina, Dave Pratt, and Don Taylor.An introduction to material handling equipment selection.College-Industry Council on Material Handling Education (CICMHE), 1998.


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