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OMSAN LOJİSTİK. Session 1 – Morning Defining the Problem Context - Supply Chain, Distribution Network - Single Warehouse Operations Logistics Activity Profiling. Session 3 – Morning Process and Technology Alternatives Small Item Picking - Order Picking Methods

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Omsan loj st k

OMSAN LOJİSTİK


Omsan loj st k

  • Session 1 – Morning

  • Defining the Problem

  • Context

    • - Supply Chain, Distribution Network

    • - Single Warehouse Operations

  • Logistics Activity Profiling

  • Session 3 – Morning

  • Process and Technology Alternatives

  • Small Item Picking

    • - Order Picking Methods

    • - Forward Pick, Slotting, and Replenishment

  • Mechanized Picking Systems

    • Zone Picking

    • Batch Picking

  • Pallet Storage

  • Session 2 – Afternoon

  • Process and Technology Alternatives

  • Pallet Storage

  • Case Picking

    • Manual

    • Mechanized

  • Session 4 – Afternoon

  • Putting it all Together

  • Developing the integrated design

    • - Sizing the Functions

    • - Defining Overall Facility Flow

    • - Orienting Shipping and Receiving

    • - Planning Aisle Patterns

  • Integrating Human Activity

Day 1

Day 2


Warehousing do you know equipment cost performance and productivity

What should one expect to pay for . . .

A lift truck? How about the battery?

Pallet rack?

How fast does a fork truck travel? An AGV?

How many cycles per hour can you achieve with . . .

A fork truck into and out of standard rack?

A turret truck into and out of Very Narrow Aisle (VNA) rack?

An Automated Storage and Retrieval System (AS/RS)?

An Automated Guided Vehicle (AGV)?

A double-deep reach truck . . .

To the first position?

To the rear position?

Warehousing—Do You Know?Equipment Cost, Performance, and Productivity


Pallet storage systems definition

What does pallet storage mean for your operation?

In new or “greenfield” projects, pallet storage requirements often define “how big” you need to make the box

In retrofit/re-engineering projects, pallet storage definition and selection determines “how much can I fit” into the current facility*

In either case, your pallet storage and retrieval decisions are heavily impacted by your business model

Pallet Storage SystemsDefinition

*TPG often refers to this as our “9 Pounds In a 5-Pound Bag” program


Pallet storage systems module outline

Storage modes

Retrieval equipment/system modes

Aisle widths

Facility height

Storage/retrieval mode relationships

Storage/retrieval mode functional and cost comparisons

Mode selection and sizing factors

Demonstration/exercise

Pallet Storage SystemsModule Outline


Pallet storage systems storage options

Pallet Storage Systems Storage Options

  • Floor Stack

  • Drive-In/Drive Through

  • Stacking Frames

  • Single-Deep Selective Pallet Rack

  • Double Deep Rack

  • Push Back Rack

  • Flow Rack

  • Cantilever Rack

  • Mobile Rack

  • Automated Storage/Retrieval System (AS/RS)


Pallet storage systems storage options1

Pallet Storage Systems Storage Options

  • Floor Stack

  • Drive-In/Drive Through

  • Stacking Frames

  • Single-Deep Selective Pallet Rack

  • Double Deep Rack

  • Push Back Rack

  • Flow Rack

  • Cantilever Rack

  • Mobile Rack

  • AS/RS


Pallet storage systems storage options2

Pallet Storage Systems Storage Options

  • Floor Stack

  • Drive-In/Drive Through

  • Stacking Frames

  • Single-Deep Selective Pallet Rack

  • Double Deep Rack

  • Push Back Rack

  • Flow Rack

  • Cantilever Rack

  • Mobile Rack

  • AS/RS


Pallet storage systems storage options3

Pallet Storage Systems Storage Options

  • Floor Stack

  • Drive-In/Drive Through

  • Stacking Frames

  • Single-Deep Selective Pallet Rack

  • Double Deep Rack

  • Push Back Rack

  • Flow Rack

  • Cantilever Rack

  • Mobile Rack

  • AS/RS


Pallet storage systems storage options4

Pallet Storage Systems Storage Options

  • Floor Stack

  • Drive-In/Drive Through

  • Stacking Frames

  • Single-Deep Selective Pallet Rack

  • Double Deep Rack

  • Push Back Rack

  • Flow Rack

  • Cantilever Rack

  • Mobile Rack

  • AS/RS


Pallet storage systems storage options5

Pallet Storage Systems Storage Options

  • Floor Stack

  • Drive-In/Drive Through

  • Stacking Frames

  • Single-Deep Selective Pallet Rack

  • Double Deep Rack

  • Push Back Rack

  • Flow Rack

  • Cantilever Rack

  • Mobile Rack

  • AS/RS


Pallet storage systems storage options6

Pallet Storage Systems Storage Options

  • Floor Stack

  • Drive-In/Drive Through

  • Stacking Frames

  • Single-Deep Selective Pallet Rack

  • Double Deep Rack

  • Push Back Rack

  • Flow Rack

  • Cantilever Rack

  • Mobile Rack

  • AS/RS


Pallet storage systems storage options7

Pallet Storage Systems Storage Options

  • Floor Stack

  • Drive-In/Drive Through

  • Stacking Frames

  • Single-Deep Selective Pallet Rack

  • Double Deep Rack

  • Push Back Rack

  • Flow Rack

  • Cantilever Rack

  • Mobile Rack

  • AS/RS


Pallet storage systems storage options8

Pallet Storage Systems Storage Options

  • Floor Stack

  • Drive-In/Drive Through

  • Stacking Frames

  • Single-Deep Selective Pallet Rack

  • Double Deep Rack

  • Push Back Rack

  • Flow Rack

  • Cantilever Rack

  • Mobile Rack

  • AS/RS


Pallet storage systems storage options9

Pallet Storage Systems Storage Options

  • Floor Stack

  • Drive-In/Drive Through

  • Stacking Frames

  • Single-Deep Selective Pallet Rack

  • Double Deep Rack

  • Push Back Rack

  • Flow Rack

  • Cantilever Rack

  • Mobile Rack

  • AS/RS


Pallet storage systems retrieval options

Pallet Storage SystemsRetrieval Options

  • Pallet jack

  • Walkie Stacker

  • Counterbalanced

  • Straddle

  • Straddle Reach

  • Turret (Swing reach)

  • Swing Mast (Drexel)

  • Sideloader

  • AS/RS


Pallet storage systems retrieval options1

Pallet Storage SystemsRetrieval Options

  • Pallet jack

  • Walkie Stacker

  • Counterbalanced

  • Straddle

  • Straddle Reach

  • Turret (Swing reach)

  • Swing Mast (Drexel)

  • Sideloader

  • AS/RS


Pallet storage systems retrieval options2

Pallet Storage SystemsRetrieval Options

  • Pallet jack

  • Walkie Stacker

  • Counterbalanced

  • Straddle

  • Straddle Reach

  • Turret (Swing reach)

  • Swing Mast (Drexel)

  • Sideloader

  • AS/RS


Pallet storage systems retrieval options3

Pallet Storage SystemsRetrieval Options

  • Pallet jack

  • Walkie Stacker

  • Counterbalanced

  • Straddle

  • Straddle Reach

  • Turret (Swing reach)

  • Swing Mast (Drexel)

  • Sideloader

  • AS/RS


Pallet storage systems retrieval options4

Pallet Storage SystemsRetrieval Options

  • Pallet jack

  • Walkie Stacker

  • Counterbalanced

  • Straddle

  • Straddle Reach

  • Turret (Swing reach)

  • Swing Mast (Drexel)

  • Sideloader

  • AS/RS


Pallet storage systems retrieval options5

Pallet Storage SystemsRetrieval Options

  • Pallet jack

  • Walkie Stacker

  • Counterbalanced

  • Straddle

  • Straddle Reach

  • Turret (Swing reach)

  • Swing Mast (Drexel)

  • Sideloader

  • AS/RS


Pallet storage systems retrieval options6

Pallet Storage SystemsRetrieval Options

  • Pallet jack

  • Walkie Stacker

  • Counterbalanced

  • Straddle

  • Straddle Reach

  • Turret (Swing reach)

  • Swing Mast (Drexel)

  • Sideloader

  • AS/RS


Pallet storage systems retrieval options7

Pallet Storage SystemsRetrieval Options

  • Pallet jack

  • Walkie Stacker

  • Counterbalanced

  • Straddle

  • Straddle Reach

  • Turret (Swing reach)

  • Swing Mast (Drexel)

  • Sideloader

  • AS/RS


Pallet storage systems retrieval options8

Pallet Storage SystemsRetrieval Options

  • Pallet jack

  • Walkie Stacker

  • Counterbalanced

  • Straddle

  • Straddle Reach

  • Turret (Swing reach)

  • Swing Mast (Drexel)

  • Sideloader

  • AS/RS


Pallet storage systems aisle options

Conventional(12-15’ aisle)

Narrow aisle(8-10’ aisle)

Conventional height

Mid-rise

Very narrow aisle(4.5-6’ aisle)

Aisle captive

Aisle to aisle

Mid-rise

High-rise

Automated storage/retrieval(4-5’ aisle)

Pallet Storage SystemsAisle Options


Pallet storage systems facility height options

Pallet Storage SystemsFacility Height Options

Mid-rise 25-40’

High rise 40-100’

Conventional 18-25’


Pallet storage systems storage mode retrieval mode relationships

Pallet Storage Systems Storage Mode/Retrieval Mode Relationships


Pallet storage systems aisle widths

Pallet Storage Systems Aisle Widths

Double Deep

Single Deep

A

A

A


Pallet storage systems retrieval options comparison

Pallet Storage Systems Retrieval Options Comparison


Pallet storage systems cost and usability comparison

Pallet Storage Systems Cost and Usability Comparison


Pallet storage systems key factors in determining storage mode

Requirement for FIFO & lot control

Typical receipt size

Handling unit received versus handling unit shipped

Turn rate of storage unit

Overall storage requirement

Overall velocity

Pick from storage versus pick from forward area

Stacking characteristics

Controls capability

Random versus storage capability

Computer visibility of locations and inventory

Directed activities

Special needs, e.g. aerosol, chemicals . . .

Pallet Storage Systems Key Factors In Determining Storage Mode


Pallet storage systems ways to size storage

Utilization study of existing operations - measure current floor space requirements and factor in future business growth

Measure current cube requirements and reapply to new storage equipment

Historical database analysis—by SKU, analyze historical inventories, receipt sizes and sales velocity and factor in business growth

ABC product/SKU analysis—categorize each SKU into classes by sales velocity:

Establish inventory targets by class

Multiply SKU cube x inventory target and sum

Service level expectations - Establish SKU or family target inventories based on economic order quantities, lead time variability, margins

Inventory simulation

Pallet Storage Systems Ways To Size Storage


Pallet storage systems example hybrid storage systems design

Pallet Storage Systems Example Hybrid Storage Systems Design

Off-Site Floor Storage

Floor Storage

Drive-In

Drive-Through

Pallet Flow Lanes

11-20

Push-Back Rack

Double Deep Rack

6-10

2-5

Pallets on-Hand

Single-Deep rack

1

Small Parts Storage

<1

Popularity


Pallet storage systems demonstration exercise

20,000 sq. ft. available for unit load storage . . .

100’ wide x 200’ long

40’ clear height

Just to be nice, there are no columns

The 100’ wide ends are both open, the 200’ sides have walls; material flows in one end and out the other

Loads are . . .

Palletized, stretch wrapped, and highly stable

Uniformly 40” wide x 48” deep x 60” high, each holds 100 cases

Floor stack height is 3 loads

Compare pallet capacity for two scenarios:

Pallet Storage Systems Demonstration/Exercise

  • Scenario 1:

  • Block stack storage

  • Counterbalance trucks

  • 2 - 12’ aisles

  • 48” square floor positions

  • Scenario 2:

  • VNA single deep w/turret trucks

  • 5 ½ ’ aisles

  • 8’ bays

  • 6 high


Pallet storage systems demonstration exercise scenario 1

Pallet Storage Systems Demonstration/Exercise – Scenario 1

  • Scenario 1:

  • Block stack storage

  • Counterbalance trucks

  • Two 12’ aisles

  • 48” square positions

  • Were it not for the inconvenience of needing aisles, this space could hold

  • 3,750 of our pallets, or

  • 375,000 cases, where

  • 200’/4’ = 50 pos

  • 100’/4’ = 25 pos

  • 25 x 50 = 1,250 pos

  • x 3 high = 3,750 pall

  • X 100 cs/pall = 375K cs

200’

100’


Pallet storage systems demonstration exercise scenario 11

Pallet Storage Systems Demonstration/Exercise – Scenario 1

  • Scenario 1:

  • Block stack storage

  • Counterbalance trucks

  • Two 12’ aisles

  • Lane depth, 4-5 pallets

  • 48” square positions

Per our spec, we need 2 12’ aisles, leaving 76’ of width, therefore . . .

200’/4’ = 50 pos

76’/4’ = 19 pos

19 x 50 = 950 pos

x 3 high = 2,850 pall

X 100 cs/pall = 285K cs

200’

100’


Pallet storage systems demonstration exercise scenario 2

Pallet Storage Systems Demonstration/Exercise – Scenario 2

  • Scenario 2:

  • VNA single deep w/turret trucks

  • 5 ½ ’ aisles

  • 8’ bays

  • 6 high

  • Assuming 14’ for each aisle/rack set, you have enough room for 7 aisles, therefore . . .

  • 200’/8’ = 25 bays

  • x 2 pos = 50 pos

  • x 6 high = 300 pall/row

  • x 14 rows = 4,200 pall

  • X 100 cs/pall = 420K cs

This one gets a little trickier, because you need to figure out how many aisles and racks you can fit in the space. In this example, one complete aisle and rack is 14’ (5.5’ aisle plus 2 x 4’ racks plus 6” flue between racks).

200’

Aisle

Left Rack

Right Rack

100’


Pallet storage systems demonstration exercise discussion points

Which scenario was better? Why?

Why did the VNA solution yield so much more capacity?

Which is more flexible?

Which is more costly to implement?

Why would you choose one over the other?

Could you imagine a hybrid situation in which both modes may be indicated?

Pallet Storage Systems Demonstration/Exercise – Discussion Points


Pallet storage systems mind the data what space you need may surprise you

Pallet Storage Systems Mind the Data—What Space You Need May Surprise You!

In this example, the facility had a high proportion of 10-deep bulk storage lanes. As the data shows, very few SKUs are right for 10-deep storage. The facility will be more efficient with a blend that includes shallower lanes and more facings.


Pallet storage systems storage sizing rules be flexible

Use sensitivity analysis to understand and explore risks

Determine if it is better to invest on the high side vs. adding incremental space later.

Have plan established for dealing with too little space

Build on or add to lease

Surge warehouse

Drop ship to customers

Improve turns on high cube items

Cross dock

Pallet Storage Systems Storage Sizing Rules—Be Flexible!


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