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
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Unit load Storage & Retrieval Handling Docking ID & Comm
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]
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Unit load Storage & Retrieval Handling Docking ID & Comm
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)
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Unit load Storage & Retrieval Handling Docking ID & Comm
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
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Unit load Storage & Retrieval Handling Docking ID & Comm
Pallet & co
Idea: creating unit load by std platformIssues: circulation, size, form
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Unit load Storage & Retrieval Handling Docking ID & Comm
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
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Unit load Storage & Retrieval Handling Docking ID & Comm
Other pallets
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Unit load Storage & Retrieval Handling Docking ID & Comm
Other type of unit load
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Unit load Storage & Retrieval Handling Docking ID & Comm
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
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Unit load Storage & Retrieval Handling Docking ID & Comm
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
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Unit load Storage & Retrieval Handling Docking ID & Comm
Industrial rack
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Unit load Storage & Retrieval Handling Docking ID & Comm
Single-deep rack
Idea: a pallet rack that has a single storage spacePro: each pallet is independently accessibleCon: too many aisles → inefficient space utilization
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Unit load Storage & Retrieval Handling Docking ID & Comm
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
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Unit load Storage & Retrieval Handling Docking ID & Comm
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
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Unit load Storage & Retrieval Handling Docking ID & Comm
Cantilever rack
Idea: structure with protruding beams to support itemsPro: suitable for irregular/long shaped productCon: strength, balancing, pallet >> carton/piece
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Unit load Storage & Retrieval Handling Docking ID & Comm
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]
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Unit load Storage & Retrieval Handling Docking ID & Comm
Pallet flow rack
Idea: a pallet rack that always brings next palletImportant: separate picking & put-awayPro: high pick density, FIFOCon: space utilization, high cost
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Unit load Storage & Retrieval Handling Docking ID & Comm
Gravity flow rack
Idea: a rack that always brings next case/carton (200+ picks/hr)Pro: high pick density, FIFOCon: space utilization, high cost
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Bin shelve
Idea: storing cabinet for case/cartonPro: cheap,Con: single access, ID, low pick density, LIFO
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Carousels
Idea: automatic storage/retriving equipment (100-200 pick/hr)Pro: no searching, securityCon: single access
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Unit load Storage & Retrieval Handling Docking ID & Comm
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
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Small storage item equipments
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Material Handling Equipment
Idea: moving items/SKUsWhere: everywhereIssue: reach, automation, space footprint, congestionExample: hand truck, forklift, conveyor
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Unit load Storage & Retrieval Handling Docking ID & Comm
Counter balance forklift truck
Idea: unit-load mover equipped with motor & hydriodicPro: very usefulCon: wide turn → wide aisle
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Unit load Storage & Retrieval Handling Docking ID & Comm
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)
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Unit load Storage & Retrieval Handling Docking ID & Comm
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
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Crane
Idea: handling equipments that moves in fixed pathsPro: flexible shape/sizeCon: restricted area, congestion with others
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Others material handling equipment
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Conveyor
What: manual/semi-auto equipment for moving pallet (no driving cab)Pro: no additional cost,Con: large moving huge std. size, fixed paths
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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].
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Dock-related equipment
Idea: making loading & unloading easierWhere: receiving & shippingIssue: weight, layout (blind spot)Example: dock door, dock leveler, staging area
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Dock doors
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Dock area
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Identification equipment
Idea: speeding receiving & shippingWhere: receiving & shippingIssue: integration with systemExample: RFID, bar code reader, magnet
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Bar code scanner & RF terminal
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Unit load Storage & Retrieval Handling Docking ID & Comm
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
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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
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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
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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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