Ieng 471 lecture 16
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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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Ieng 471 lecture 16

IENG 471 - Lecture 16

Warehouse Operations – Facility

IENG 471 Facilities Planning


Warehousing terms

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


Warehousing metrics

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


Warehousing functions

Warehousing Functions

  • Receiving

  • Quality Inspection

  • Repackaging

  • Put-away

  • Storage

  • Order-picking (postponement)

  • Sortation & Accumulation

  • Packaging & Shipping

  • Cross-Docking

  • Replenishment

IENG 471 Facilities Planning


Receiving operations

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


Shipping operations

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


Facility accommodations for s r

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


Shipping receiving analysis

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


Sku analysis

SKU Analysis

IENG 471 Facilities Planning


Truck access

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


90 o apron space

90o Apron Space

  • Aprons are space allotted for spotting a vehicle – maneuvering room to align with the dock

IENG 471 Facilities Planning


Angled apron space finger docks

Angled Apron Space (Finger Docks)

  • Angled Aprons

    allow for access to tighter spaces

IENG 471 Facilities Planning


Material handling equipment space

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


Storage space analysis

Storage Space Analysis

IENG 471 Facilities Planning


Design of warehousing space

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


Questions issues

Questions & Issues

IENG 471 Facilities Planning


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