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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

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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