Chapter 11: Strategic Leadership Chapter 11 The design of storage and handling facilities.

Chapter 11: Strategic Leadership

Chapter 11

The design of storage and handling facilities


Overview

This chapter covers the following topics:• Introduction

• Initial requirements

• Sizing the warehouse

• Operation and warehouse management systems (WMS)

• Design process

• Fire

• Security

• Lighting


Introduction

• Need to understand the principles of the layout of a facility

• Allows change that is efficient

• Introduces the principles of change or mere expansion

• Ongoing changes to a facility requiring adaptation and improvement

• The design for a new facility is specialised and

beyond this text


Design requirements

• Should be written and reviewed before any change

• Purpose needs to be explicitly defined:

- Cross dock

- Manufacturing storage warehouse

- Distribution centre (and so on)

• Growth forecast

-Sets the size of any change to cater for the future

• Purpose of a facility is defined by a PPC


Operations and WMS

• Define the methods supported by the warehouse management system (WMS) and what is most efficient for the operation.

• Chart the processes.

• Identify limitations.

• Find solutions that are permitted and suit the operation.


Design process

• Identify PPCs in the products and processes

• For each PPC, record:

- Storage requirements

- Handling and moving areas

- Assembly areas for transport loading and unloading

-Receiving requirements


PPC combination and optimisation

• Define for each PPC:

- Which areas are unique to the PPC

- Which areas can be combined and the impact on space or congestion

-Periods of operation


Common areas

• If common areas are used in same period, then require increased space above single use, but less than proportion to number of PPCs that will use space.

• Example: a travel aisle for two PPCs need only be 50% wider than that required for one PPC use.


Aisle sizes between/around racks • Aisle size is determined by equipment

used and traffic .

• Rack volume to total floor space is important to know, as directly influences quantity of product to be stored – must be able to calculate this.


Methods – receiving

• Interaction between receipt and put-away determines size of receiving area.

• Disciplined placing in lines at all times makes for smaller size.

• Partial receipt before put-away begins reduces size necessitated by receiving area.


Layout of receiving bay


Movement zones

Defined to cater for all movement that will occur, reflecting:

• Number of PPCs that will use it concurrently (defined by periods of use)

• Speed of equipment

• Turning and stopping

• Flows – one- or two-way increase the size of movement area


Other requirements

• Pick method• Loading/unloading doors• External truck area


Combining areas

• Requirements for each PPC

• Can use CAD or drawing method

• Drawing method:

- Record areas on paper layouts (cut out)

- Move around on drawing of facility

- Unique areas must be allocated so temperatures are graded from lowest to highest and flows are sensibly minimised

- Common areas must be combined


Other issues

• Fire

• Safety

• Security

• Lighting

Chapter 11: Strategic Leadership Chapter 11 The design of storage and handling facilities.

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Transcript of Chapter 11: Strategic Leadership Chapter 11 The design of storage and handling facilities.