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OutlineOutline

putaway pallet storage and retrieval case retrieval project

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Operations in WarehousesOperations in Warehouses

receiving prepackaging (optional) putaway storage order picking packaging and/or pricing (optional) sorting and/or accumulation unitizing and shipping

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Putaway PrinciplesPutaway PrinciplesPutaway: The logistics process in a warehouse to put an incoming load after Putaway: The logistics process in a warehouse to put an incoming load after

receiving to its final storage locationreceiving to its final storage location

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Points to DiscussPoints to Discuss

putaway touch reduction, distance reduction, efficiency improvement

pallet storage and retrieval effect of rack type

effect of layout

factors to select pallet storage equipment

pallet retrieval equipment

pallet retrieval

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Putaway PrinciplesPutaway Principles

primary objective: touch reduction and process streamlining

touch reduction: in increasing number of touches

direct shipping

cross-docking

primary picking locations

permanent storage

marshalling area

*

how to reduce travel distance?

batched and sequenced putaway

interleaving and continuous moves

Distance Reduction in PutawayDistance Reduction in Putaway

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directed putaway

using WMS to direct storage locations

benefits: to maximize storage location utilization, product rotation, retrieval productivity

Efficiency ImprovementEfficiency Improvement

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Storage SystemStorage System

classification by size pallets, boxes, small items

two types of equipment storage and retrieval

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Pallet Storage and Retrieval Pallet Storage and Retrieval

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Pallet Storage SystemPallet Storage System

storage racks Floor Storage, Stacking Frames, Single-Deep, Double-

Deep, Drive-in Rack, Drive Thru, Flow Rack, Push Back, Mobile Rack, Cantilever

retrieval equipment Counter-balance, Straddle, Straddle Reach, Side-loader,

Turret, Hybrid, AS/RS

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Effect of Rack Type and LayoutEffect of Rack Type and Layout

characteristics varying with rack type example: single-deep versus double-deep

a venue of 109 slots with the door at the middle of the 10-slot side

aisle of one slot wide which one is better, single- or double-deep?

statistics utilization of area for:

33 different types of pallets 49 different types of pallets

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Pallet Systems: Block StackingPallet Systems: Block Stacking

factors to consider safe limits, load stackability, load weights,

pallet conditions, floor loading restrictions, weather, vehicle life, height capacity, crushability of the loads, building clear height

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cost per position, position storage density, load access, throughput capacity, inventory & location control, FIFO maintenance, ability for variable load, ease of installation

Factors to Select Factors to Select the Pallet Storage Equipmentthe Pallet Storage Equipment

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Pallet Storage SelectionPallet Storage Selection

ease of installation

ability for variable load

FIFO maintenance

inv. & location cont.

throughput capacity

load access

position storage den.

cost per position

Can-tilever

Mobile Rack

Push Back

Flow Rack

Drive Thru

Drive-in Rack

Double-Deep

Single-Deep

Stacking Frames

Floor Storage

BFCFCCCCAA

BCCFDDCCDA

ACCADDCAFF

BDCCDDCAFF

CFCACCCBDB

AFABBBCAFF

BABBBBCDBA

$80$250$150$200$65$65$50$40$50n/a

A: excellent; B: above average; C: average; D: below average; F: failure

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Pallet Storage SelectionPallet Storage Selection

ease of installation

ability for variable load

FIFO maintenance

inv. & location cont.

throughput capacity

load access

position storage den.

cost per position

Can-tilever

Mobile Rack

Push Back

Flow Rack

Drive Thru

Drive-in Rack

Double-Deep

Single-Deep

Stacking Frames

Floor Storage

A: excellent; B: above average; C: average; D: below average; F: failure

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Pallet Storage and Economic Pallet Storage and Economic Analysis Analysis

Pallet Flow Lanes

Push Back Rack

Double Deep Rack

Single-Deep Rack

Mobile Storage

Off-Site Floor

StoragePallets On

Hand

Popularity

1

11-12

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vehicle cost, life height capacity, aisle width, weight capacity, life speed, travel speed

Factors to Select Factors to Select Pallet Retrieval EquipmentPallet Retrieval Equipment

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Pallet Retrieval System ComparisonPallet Retrieval System Comparison

Travel speed

Lift speed

Weight capacity

Aisle width

Life height capacity

Vehicle Cost

AS/RSHybridTurretSide-loader

Straddle Reach

StraddleCounter-

balance

700 fpm490 fpm490 fpm440 fpm490 fpm470 fpm550 fpm

200 pfm60 pfm75 pfm50 pfm50 pfm60 pfm80 pfm

2 - 5 k2 - 4 k3 - 4 k2 - 10 k2 - 5 k2 - 6 k2 - 10 k

4.5 ft5 ft5 – 7 ft5 – 7 ft6 – 8 ft7 – 9 ft10 – 12 ft

75 ft50 ft40 ft30 ft30 ft21 ft22 ft

$200K$125K$ 95K$ 75K$ 40K$ 35K$30K

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Miscellaneous IssuesMiscellaneous Issues

trade-off between aisle width & depth honeycombing effect

co-existence of several systems in a warehouse flow racks for fast moving goods & single-deep

racks for slow moving goods

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Case Picking SystemsCase Picking Systems

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Case Picking SystemsCase Picking Systems

When is it unnecessary to discuss case storage systems? incoming in pallet form

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Case Picking SystemsCase Picking Systems

decisions how to pick

palletizing or not if so, where and how

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Case Picking SystemsCase Picking Systems

how to do it in lativ

Amazon

the distribution center of Shiseido discussed before

20112011

20102010

20092009

20082008

20072007

Rev. (NT$)Rev. (NT$)Year

> 4 billion> 4 billion

1.5 billion1.5 billion

370 million370 million

100 million100 million

10 million10 million

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Case Picking SystemsCase Picking Systems

decisions: palletizing or not; if so, where and how

three types pick face palletizing system downstream palletizing system direct loading system (no palletization)

criteria goods characteristics, costs, pick rates

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Pick Face Palletizing SystemsPick Face Palletizing Systems

palletizing during picking pallet jack picking lift truck picking pallet trains order picker trucks end-of-aisle AS/RS robotic case picking

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Downstream PalletizingDownstream Palletizing

two components, conveying to downstream and palletizing there

conveying downstream pick-to-conveyor

sort-ing

case sorting systems pick-car systems automated case dispensing tier (or layer) picking

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Downstream PalletizingDownstream Palletizing

palletizing systems manual palletizing mechanical palletizing robotic palletizing

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Case Picking System Case Picking System and Productivity Characteristicsand Productivity Characteristics

Tier Picking

Auto Extract

End-ofAisle AS/RS

Pick to Belt

Pick to Roller

Order Picker Truck

Pallet Jack

Initial CostPicking Rates

$150K/unit1,000-1,500

$200K/unit = $130/lane500-800

$300K to $450K /aisle200-300

$200/ft + $2K/divert250-400

$1K/ft125-250

$30K/vehicle50-100

$1K to @10 K /vehicle100-250

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The Main QuestionThe Main Question

how to design a warehouse system

combination of equipment

layout

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ProjectProject

individual project

on a topic related to warehousing, warehouses,

or both

discussing with Wan before finalizing the topic

three components: proposal, final presentation,

and report

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ProjectProject

proposal: a 10-minute presentation, possibly including the following

introducing the problem

explaining its importance, relevance, and value

describing your procedure, method, expected results

final presentation: 10 minutes

report

(at least) 10 A4 pages

one a half line spacing

12-ponit Times New Roman font

following the format of a technical paper

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Papers for the Second Half SemesterPapers for the Second Half Semester

put in the general office