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 1  Outline  putaway  pallet storage and retrieval  case retrieval  project.

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Presentation on theme: " 1  Outline  putaway  pallet storage and retrieval  case retrieval  project."— Presentation transcript:

1  1  Outline  putaway  pallet storage and retrieval  case retrieval  project

2  2  Operations in Warehouses  receiving  prepackaging (optional)  putaway  storage  order picking  packaging and/or pricing (optional)  sorting and/or accumulation  unitizing and shipping

3  3  Putaway Principles Putaway: The logistics process in a warehouse to put an incoming load after receiving to its final storage location

4  4  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

5  5  Putaway 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

6  6   how to reduce travel distance?  batched and sequenced putaway  interleaving and continuous moves Distance Reduction in Putaway

7  7   directed putaway  using WMS to direct storage locations  benefits: to maximize storage location utilization, product rotation, retrieval productivity Efficiency Improvement

8  8  Storage System  classification by size  pallets, boxes, small items  two types of equipment  storage and retrieval

9  9  Pallet Storage and Retrieval

10  10  Pallet Storage System  storage racks storage racks  Floor Storage, Stacking Frames, Single-Deep, Double- Deep, Drive-in Rack, Drive Thru, Flow Rack, Push Back, Mobile Rack, Cantilever  retrieval equipment retrieval equipment  Counter-balance, Straddle, Straddle Reach, Side-loader, Turret, Hybrid, AS/RS

11  11  Effect of Rack Type and Layout  characteristics varying with rack type  example: single-deep versus double-deep  a venue of 10  9 slots with the door at the middle of the 10-slot side a venue of 10  9 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? which one is better, single- or double-deep?  statistics statistics  utilization of area for:  33 different types of pallets  49 different types of pallets

12  12  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

13  13   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 the Pallet Storage Equipment

14  14  Pallet 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 $50$40$50n/a A: excellent; B: above average; C: average; D: below average; F: failure

15  15  Pallet 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

16  16  Pallet Storage and Economic Analysis Pallet Flow Lanes Push Back Rack Double Deep Rack Single-Deep Rack Mobile Storage Off-Site Floor Storage Pallets On Hand Popularity

17  17   vehicle cost, life height capacity, aisle width, weight capacity, life speed, travel speed Factors to Select Pallet Retrieval Equipment

18  18  Pallet Retrieval System Comparison Travel speed Lift speed Weight capacity Aisle width Life height capacity Vehicle Cost AS/RSHybridTurretSide- loader Straddle Reach Straddle Counter- balance 700 fpm490 fpm 440 fpm490 fpm470 fpm550 fpm 200 pfm60 pfm75 pfm50 pfm 60 pfm80 pfm k2 - 4 k3 - 4 k k2 - 5 k2 - 6 k k 4.5 ft5 ft 5 – 7 ft 6 – 8 ft7 – 9 ft 10 – 12 ft 75 ft50 ft40 ft30 ft 21 ft22 ft $200K$125K$ 95K$ 75K$ 40K$ 35K$30K

19  19  Miscellaneous 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

20  20  Case Picking Systems

21  21  Case Picking Systems  When is it unnecessary to discuss case storage systems?  incoming in pallet form

22  22  Case Picking Systems  decisions  how to pick  palletizing or not  if so, where and how

23  23  Case Picking Systems  how to do it in  lativ lativ  Amazon Amazon  the distribution center of Shiseido discussed before Rev. (NT$) Year > 4 billion 1.5 billion 370 million 100 million 10 million

24  24  Case 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

25  25  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

26  26  Downstream 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

27  27  Downstream Palletizing  palletizing systems  manual palletizing  mechanical palletizing  robotic palletizing

28  28  Case Picking System and 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/lane $300K to $450K /aisle $200/ft + $2K/divert $1K/ft $30K/vehicle $1K K /vehicle

29  29  The Main Question  how to design a warehouse system  combination of equipment  layout

30  30  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

31  31  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  (at least) 10 A4 pages  one a half line spacing  12-ponit Times New Roman font  following the format of a technical paper

32  32  Papers for the Second Half Semester  put in the general office


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