warehouse equipment
TRANSCRIPT
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Warehousing Equipment
Tompkins et al., Facilities Planning, John Wiley
& Sons, 1996: Chapters 6, 9
College-Industry Council on Material Handling
Education: Material Handling EquipmentTaxonomy: http://www.mhia.org/et/mhe_tax.htm
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The role of equipment in warehouseoperations
Reduce cost (labor + space) enhance space utilization by, e.g.,
enabling the exploitation of the vertical dimension of the facility
allowing for denser packing
allow for more efficient order-picking by, e.g.,
increasing the sku density supporting the automated transfer of material from storage to sorting
and consolidation area
Enhance responsiveness
increase the throughput of the facility, e.g.,
increasing the sku density establishing a more ergonomic environment/arrangement for the
warehouse operators
facilitating the parallelization of order picking
by parallelizing the tasks of order-picking and replensihment
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The role of equipment in warehouseoperations (cont.)
Maintain Quality of Product and Operations
provide an orderly storage environment
provide efficient ways for product tracing and identification
provide safe and secure material handling
facilitate order sortation and consolidation
establish and maintain a controlled environment e.g.,
temperature control
access control
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Equipment Classification
(Tompkins et. al., pgs 170-173) Containers & Unitizing Equipment
Storage and Retrieval Equipment
Unit Load
Small Load
Conveyors
Warehouse docks and dock-related equipment
Automatic Identification and Communication Equipment
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For detailed functional descriptions,discussion on supported efficiencies,
and pictures
College-Industry Council on Material Handling
Education: Material Handling Equipment
Taxonomy:http://www.mhia.org/et/mhe_tax.htm
Tompkins et al., Facilities Planning, John
Wiley & Sons, 1996: Chapters 6, 9
http://www.mhia.org/et/mhe_tax.htmhttp://www.mhia.org/et/mhe_tax.htm -
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Pallet Storage Modes
Block Stacking
Rack Storage
Single-Deep
Double-Deep
Drive-In/Through
Pallet Flow
Unit Load AS/RS
etc.
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Block Stacking (or Floor Storage)
LanesLane Depth
(3-deep)
Lane Height
An efficient storage mode when
there are multiple pallets per SKU; inventory is turned in large increments, I.e., several loads of the same SKU
are received or withdrawn at one time.
Main problems:
Loss of space due to honeycombing not effective utilization of the vertical dimension of the facility
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Selective or Single-Deep or SimplePallet Rack
The benchmark storage mode
Due to rack supports, each pallet is independently
accessible (i.e. it supports totally random access)
Trade-off: too many aisles => inefficient space utilization
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Double-deep rack
Two selective racks placed back-to-back => 2-deep lanes
Each lane dedicated to one SKU => space loss in case of
SKUs with odd number of pallets
Less aisle space required (upto 50% savings in aisle space)
Trade-off: More work and/or specialized equipment forretrieving
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Other pallet rack types
Drive-In/Through rack: 5-10 loads deep Better space utilization
More difficult, even dangerous retrieval
Pallet flow rack: up to 8 pallets deep The rack shelves are slanted and have rollers, and therefore, every
time a pallet is retrieved from a lane, the pallet behind it takes its
position.
Allows for simultaneous picking and restocking
Supports FIFO operation
Typically used in high-throughput facilities
Cantilever rack:
Supports long items like timber and pipes
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Unit-Load Retrieval Equipment
Key Differentiation factors:
aisle width requirements
lift height/weight capacity
Lane depth they can reach
degree of automation
capital expense
Major types
Walkie Stacker
Counterbalance Lift Truck
Narrow Aisle Vehicles Automated Storage/Retrieval Machines
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Small Load Storage and RetrievalEquipment
Operator-to-Stock(or Man-to-Part or in-the-aisle) system:the operator travels to the storage location to retrieve
material
Stock-to-Operator (or Part-to-Man or end-of-aisle) system:
the material is mechanically transported to the operator forretrieval
Advantages of STO:
higher productivity
easier supervision better item security and protection
Disadvantages of STO:
more expensive
more maintenance
more difficult to reconfigure
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Operator-to-Stock Storage Equipment
Bin Shelving
Modular Storage Drawers in Cabinets
Carton Flow Racks
Mobile Storage
All the above equipment can also be arranged in
mezzanines to get a better exploitation of the building
cube.
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Operator-to-Stock Retrieval Equipment
Picking Cart
Order Picker Truck (for higher placed loads)
Person-aboard Automated Storage/Retrieval Machine
captive aisle
free roaming
(Robotic Retrieval)
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Stock-to-Operator Equipment
Carousels
Horizontal
Vertical
Independently Rotating Racks
Miniload Automated Storage and Retrieval Machine
Automatic Dispenser
Productivity gains Allow for extensive parallelization of order retrievals
Focus on extracting rather than traveling and searching
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Conveyors
(Flat) Belt
Roller
Telescoping Belt
Chute
Sorting
Deflector
Push Diverter
Pop-up Skewed Wheels
Pop-up Roller
Tilt tray
Remarks:
Conveyors change the economics of travel.
They can partition physically the warehouse into zones
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Warehouse docks and dock-relatedequipment
Warehouse docks: The facility interface with the shipping
carriers
Dock configurations and dimensioning
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Equipment facilitating the interfacingbetween docks and shipping carriers
Dock levelers: compensate the height difference betweenthe carrier platform and the dock door
mobile yard ramps
permanent adjustable dock boards
truck levelers
scissors-type lifting docks
Bumper pads: absorb the shock from the impact of the
shipping trailer with the dock walls (laminated rubber
cushions)
40,000 lb load traveling 4 mph => 150,000 lb force
Dock shelter: a flexible shield that when engaged to the
carrier provides a closed-environment interface between it
and the inner area of the warehouse
energy savings, increased safety, product protection, etc.
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Automatic Identification andCommunication Equipment
Permits real-time, nearly flawless data collection andcommunication, and therefore, it facilitates and increases
the real-time awareness of the location, amount, origin,
destination and schedule of the material.
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Automatic Identification andRecognition
Bar coding technology:
bar codes
bar code readers
bar code printers
Optical character recognition
Radio Frequency (RF) and Surface Accoustical Wave
(SAW) tags
Magnetic Stripes
Machine Vision
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Automatic Paperless Communication
RF data terminal Voice headset
Light and Computer Aids
Smart card