Receiving, Putaway, Pallets, and Cases
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Transcript Receiving, Putaway, Pallets, and Cases
Outline
putaway
pallet
storage and retrieval
case retrieval
project
1
Operations in Warehouses
receiving
prepackaging (optional)
putaway
storage
order picking
packaging and/or pricing (optional)
sorting and/or accumulation
unitizing and shipping
2
Putaway Principles
Putaway: The logistics process in a
warehouse to put an incoming load
after receiving to its final storage location
3
Points 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
4
Putaway Principles
primary
objective: touch reduction and
process streamlining
touch
reduction: in increasing number of
touches
primary picking
locations
permanent storage
direct shipping
marshalling area
5
cross-docking
Distance Reduction in Putaway
how
to reduce travel distance?
batched
and sequenced putaway
interleaving
and continuous moves
6
Efficiency Improvement
directed
using
putaway
WMS to direct storage locations
benefits:
to maximize storage location utilization,
product rotation, retrieval productivity
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Storage System
classification
pallets,
two
by size
boxes, small items
types of equipment
storage
and retrieval
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Pallet Storage and Retrieval
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Pallet Storage System
storage
racks
Floor Storage, Stacking Frames, Single-Deep, DoubleDeep, 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 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 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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Factors to Select
the Pallet Storage Equipment
cost
per position, position storage density,
load access, throughput capacity, inventory
& location control, FIFO maintenance,
ability for variable load, ease of installation
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Pallet Storage Selection
Floor
Storage
Stacking
Frames
SingleDeep
DoubleDeep
Drive-in
Rack
n/a
$50
$40
$50
$65
$65
position
storage den.
A
B
D
C
B
B
B
B
A
B
load access
F
F
A
C
B
B
B
A
F
A
throughput
capacity
B
D
B
C
C
C
A
C
F
C
inv. & location
cont.
F
F
A
C
D
D
C
C
D
B
FIFO
maintenance
F
F
A
C
D
D
A
C
C
A
ability for
variable load
A
D
C
C
D
D
F
C
C
B
ease of
installation
A
A
C
C
C
C
F
C
F
B
cost per
position
Drive
Thru
Flow
Rack
Push
Back
Mobile
Rack
$200 $150 $250
A: excellent; B: above average; C: average; D: below average; F: failure
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Cantilever
$80
Pallet Storage Selection
Floor
Storage
Stacking
Frames
SingleDeep
DoubleDeep
Drive-in
Rack
Drive
Thru
Flow
Rack
Push
Back
Mobile
Rack
cost per
position
position
storage den.
load access
throughput
capacity
inv. & location
cont.
FIFO
maintenance
ability for
variable load
ease of
installation
A: excellent; B: above average; C: average; D: below average; F: failure
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Cantilever
Pallet Storage and Economic
Analysis
11-12
Off-Site
Floor
Storage
Pallets On
Hand
Mobile
Storage
1
Pallet Flow
Lanes
Double
Deep
Rack
Push
Back
Rack
Single-Deep Rack
Popularity
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Factors to Select
Pallet Retrieval Equipment
vehicle cost, life height capacity, aisle width,
weight capacity, life speed, travel speed
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Pallet Retrieval System Comparison
Counterbalance
Straddle
Straddle
Reach
Sideloader
Turret
Hybrid
AS/RS
Vehicle Cost
$30K
$ 35K
$ 40K
$ 75K
$ 95K
$125K
$200K
Life height capacity
22 ft
21 ft
30 ft
30 ft
40 ft
50 ft
75 ft
Aisle width
10 – 12 ft
7 – 9 ft
6 – 8 ft
5 – 7 ft
5 – 7 ft
5 ft
4.5 ft
Weight capacity
2 - 10 k
2-6k
2-5k
2 - 10 k
3-4k
2-4k
2-5k
Lift speed
80 pfm
60 pfm
50 pfm
50 pfm
75 pfm
60 pfm
200 pfm
Travel speed
550 fpm
470 fpm
490 fpm
440 fpm
490 fpm
490 fpm
700 fpm
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Miscellaneous Issues
trade-off
between aisle width & depth
honeycombing
co-existence
effect
of several systems in a
warehouse
flow
racks for fast moving goods & single-deep
racks for slow moving goods
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Case Picking Systems
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Case Picking Systems
When
is it unnecessary to discuss case
storage systems?
incoming
in pallet form
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Case Picking Systems
decisions
how to pick
palletizing or not
if so, where and how
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Case Picking Systems
Year
2007
2008
2009
2010
2011
how to do it in
Rev. (NT$)
10 million
100 million
370 million
1.5 billion
> 4 billion
lativ
Amazon
the distribution center of Shiseido discussed before
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Case Picking Systems
decisions: palletizing or not; if so, where and
how
three types
pick
face palletizing system
downstream
direct
palletizing system
loading system (no palletization)
criteria
goods
characteristics, costs, pick rates
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Pick 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 Palletizing
two
components, conveying to downstream
and palletizing there
conveying downstream
pick-to-conveyor
case
sorting systems
pick-car systems
automated case dispensing
tier (or layer) picking
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sorting
Downstream Palletizing
palletizing
systems
manual
palletizing
mechanical palletizing
robotic palletizing
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Case Picking System
and Productivity Characteristics
Picking Rates
Initial Cost
Pallet Jack
100-250
$1K to @10 K /vehicle
Order Picker Truck
50-100
$30K/vehicle
Pick to Roller
125-250
$1K/ft
Pick to Belt
250-400
$200/ft + $2K/divert
End-ofAisle AS/RS
200-300
$300K to $450K /aisle
Auto Extract
500-800
$200K/unit = $130/lane
Tier Picking
1,000-1,500
$150K/unit
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The Main Question
how
to design a warehouse system
combination
of equipment
layout
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Project
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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Project
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
10 A4 pages
(at least)
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 Semester
put
in the general office
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