Transcript Racking In The Foodservice Warehouse

Racking In The
Foodservice Warehouse
W. Frank Dell CMC
President
DELLMART & Company
125 Hardesty Road
Stamford, CT 06903
Agenda
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INTRODUCTION
RACKING OPTIONS
MECHANIZATION OPTIONS
EQUIPMENT OPTIONS
DESIGN ISSUES
SUMMARY
DELLMART & COMP
MANAGEMENT CONSULTANTS
Objectives
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Explore different types of racking or storage
mediums
Understand the advantages and disadvantages
of each type
Review the supporting equipment
Warehouse Design Rational Include
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Store Capacity
Selection Slots
Labor Productivity
Through-Put
Terminology For Warehouse Processes
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Inbound
 Receiving
 Put-Away
Outbound
 Replenishment
 Selection
 Loading
Procurement’s Impact On
Warehouse Requirements
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Storage Capacity
Selection Slots
Receiving Doors & Dock Space
Storage Type
Pallet Size Should Be Determined
Jointly By Buying And Warehousing
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Cycle Stock = Pallet Quantity
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Pallet Quantity =
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Ordering Concepts
 Fixed
Review
 Just In Time
2 X Put Away Cost
Holding Cost
Customer’s Impact On
Warehouse Requirements
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Sales Volume
Order Size
Pick Density
Number of Orders
Shipping Doors and Dock Space
Direct Labor Fundamentals
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Every task has a fixed time component
Travel Standards
 Walk
 Ride
 LIft
Case Handling Standards
 Case
 Cube
 Weight
Agenda
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INTRODUCTION
RACKING OPTIONS
MECHANIZATION OPTIONS
EQUIPMENT OPTIONS
DESIGN ISSUES
SUMMARY
DELLMART & COMP
MANAGEMENT CONSULTANTS
Floor Stack
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Usage - Selection, reserve and bulk storage
Application
 Large case cube
 High velocity
 Low roof
Advantages
Disadvantages
Floor space utilization
2 Replenishment per 3 selection pallets
Flexible deep
Minimal capital cost
Height restriction (Max. 3 pallets high)
Product rotation
Product damage
Single Deep One High Select
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Usage - Selection floor slot with reserve overhead
Application
 Large case cube
 Fast seller
Advantages
Simple to manage
Good height utilization
Disadvantages
Reduce slot cube utilization
Single Deep Two High Select
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Usage - Selection floor slots with reserve overhead
Application
 Medium cube and velocity
 Small cube and high velocity
Advantages
Increase selection slots
Increase selection density
Reduce walk time
Disadvantages
Reduce cube utilization
Single Deep Three High Select
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Usage - Selection floor slots with reserve overhead
Application
 Small cube
 Slow velocity
Advantages
Increase selection slots
Increase selection density
Reduce walk time
Disadvantages
Reduce cube utilization
Reduce selection capacity
Slower replenishment
Single Deep Hand Stack
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Usage - Selection floor slot with no reserve storage
Application
 Small cube
 Very slow velocity
 Broken case items
Advantages
Increase selection slots
Increase selection density
Reduce walk time
Disadvantages
Reduce cube utilization
Reduce selection capacity
Slower put-away
Increase rotation problems
Increase selection errors
Case Flow Rack
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Usage - Selection with reserve in lane and bulk
storage overhead
Application
 Case cube less than 1
 Case velocity less than 11
Advantages
High selection density
Keeps family groups together
Disadvantages
Must be linked to buying
Double Deep One High Select
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Usage - Selection floor slot with reserve
overhead and behind
Application
 Large case cube
 Fast seller
Advantages
Good storage capacity
Disadvantages
Difficult to replenish and put-away
Increase rotation problems
Drive in Rack
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Usage - Selection floor slots with reserve overhead
Application
 Large case cube
 High Velocity
 Buying restriction
Advantages
Multiple selection slots
Maximum selection capacity
Disadvantages
Increase rotation problems
Creates honey combing
Agenda
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INTRODUCTION
RACKING OPTIONS
MECHANIZATION OPTIONS
EQUIPMENT OPTIONS
DESIGN ISSUES
SUMMARY
DELLMART & COMP
MANAGEMENT CONSULTANTS
Pick To Belt
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Application
 Medium size cases
 Fast and medium velocity
Advantages
High selection rate
Controlled walk
Batch select
Disadvantages
Requires sorting step
Must walk entire system
Non-conveyable cases
Carousel
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Application
 Smaller cases
 Slow velocity
Advantages
Random selection
Reduce travel
Disadvantages
Lose overhead storage
Limitation on case size
Slow replenishment
Cartrac
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Application
 Medium and large cases
 High velocity with multi-carts
Advantages
Reduce travel
Batch selection
Disadvantages
Lose overhead storage
Difficult to replenish
Program Item Retrieval (PIR)
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Application
 Small and medium cases
 Slow velocity
Advantages
Increase selection slots
Random slots
Batch select
Disadvantages
Require sorting step
Machine paces travel
Slower put-away
Agenda
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INTRODUCTION
RACKING OPTIONS
MECHANIZATION OPTIONS
EQUIPMENT OPTIONS
DESIGN ISSUES
SUMMARY
DELLMART & COMP
MANAGEMENT CONSULTANTS
Fork Lifts
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Counter balance - wide aisle
Straddle - narrow aisle
Stand-up versus ride
Fork Lift Attachments
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Pallet forks
Slip sheet or push-pull
Clamp
Reach
Single Pallet Jack
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Dock Jockey
Put-away into floor slot
Put-away transport
Selection
Double Pallet Jack (Long John)
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Put-away transport
Selection
 Single orders
 Batch orders
Tugger
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Carts or trucks
Radio control
Agenda
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INTRODUCTION
RACKING OPTIONS
MECHANIZATION OPTIONS
EQUIPMENT OPTIONS
DESIGN ISSUES
SUMMARY
DELLMART & COMP
MANAGEMENT CONSULTANTS
Narrow Versus Wide Aisle
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Less floor square feet
Greater cube utilization
Facilitates 2 side selection
Increases congestion and interference
Increases damage
Slot Column
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Spacing
 Maneuvering room
 Product
 Pallet
 Bar
Bury columns
Number of slot types
Rack Bar
Product
Pallet
Rack Bar
Cross Bars
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Pair weight
Adjustability
Height Versus Floor
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Land cost
24 foot rule
Slotting
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Family grouping
Velocity
Customer orders
Density
Layout Check List
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Dock space
Employee area and facilities
Battery charging area
Repair and maintenance area
Damage and return processing
Agenda
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INTRODUCTION
RACKING OPTIONS
MECHANIZATION OPTIONS
EQUIPMENT OPTIONS
DESIGN ISSUES
SUMMARY
DELLMART & COMP
MANAGEMENT CONSULTANTS
Summary
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Plan 5 years into the future
Rank design rationale
Test alternatives with labor models
Perform quarterly maintenance
Thank for Providing Slides
Clark
Crown
Hi-Line
Hyster
Interlake
Raymond
SI Handling
White
Yale