Chapter 10 Warehousing and Material Handling 仓储和物料搬运

AIMS OF THE CHAPTER ■ APPRECIATE the purpose and aims of warehouses ■ DESCRIBE the main activities in a warehouse ■ COMPARE the benefits of private and public warehousing ■ APPRECIATE the purpose of packaging

10.1 PURPOSE OF WAREHOUSES 10.1.1 definition of warehouse A WAREHOUSE is any location where stocks of material are held on their journey through supply chains. As well as storage, warehouses can be used for a number of other activities

10.1 PURPOSE OF WAREHOUSES 10.1.1 definition of warehouse When we talk about warehouses storing materials, this is really only part of the story. Many organizations are using warehouses as convenient locations for doing a range of related jobs. For example, labeling, packaging, making products ‘store ready’ for retailers, doing other aspects of postponement, servicing vendor managed inventories, and so on. The overall trend is for warehouses to do more tasks

10.1 PURPOSE OF WAREHOUSES 10.1.2 Fitting into the logistics strategy Important factors you have to consider when choosing size for warehouse: the number of products using the warehouse the type of demand for each product, how much it varies, average order size, and so on physical features of the products, particularly size and weight

10.1 PURPOSE OF WAREHOUSES special storage conditions, such as climate control, packaging, and so on target customer service level lead times from suppliers and promised to customers economies of scale type of material handling equipment layout of storage and related facilities.

10.2 ACTIVITIES IN WAREHOUSE 10.2.1 Basic activities receiving goods from upstream suppliers identifying the goods, matching them to orders and finding their intended use unloading materials doing checks on quantity, quality and condition labelling materials (usually with bar codes) sorting goods as needed moving goods to bulk storage area holding them in stock until needed

10.2 ACTIVITIES IN WAREHOUSE 10.2.1 Basic activities moving materials from bulk storage to a smaller picking store picking materials from this store to meet orders moving the materials to a marshalling area assembling materials into orders packing and packaging loading delivery vehicles and dispatching the order controlling all communications and related systems

10.2 ACTIVITIES IN WAREHOUSE 10.2.2 other activities sorting materials, packing consolidating deliveries.

YOU KNOW WHAT? A computer manufacturer, for example, might collect in a central warehouse a keyboard from Brazil, software from the USA, a monitor from the UK, speakers from Taiwan and the main box from Japan, and so on. The warehouse assembles the components into final systems and delivers them to customers.

10.2 ACTIVITIES IN WAREHOUSE 10.2.12 other activities

10.2 ACTIVITIES IN WAREHOUSE 10.2.2 other activities The consolidation can go further than simply bringing together materials from different sources. It might add the final packing and packaging to present a single product, or even do a limited amount of final manufacturing. This is the basis of postponement

10.2 ACTIVITIES IN WAREHOUSE Warehouses are increasingly places for sorting and doing work on materials rather than storing them. In the extreme they do these associated jobs, but the materials are never put into storage. This is the basis of cross-docking.

10.3 OWNSHIP Private warehouses are owned or leased by an organization as part of its own supply chains. The organization runs its own warehouses to support its main operations. This gives greater control over a central part of logistics, and allows integration of warehousing with the broader activities of logistics

10.3 OWNSHIP A public warehouse is run as an independent business, which makes money by charging users a fee. There are many types of public warehouse, including bonded warehouses, cold stores, bulk storage, tankers and various specialty stores. Comparison: Private warehouses have higher fixed costs but lower unit operating costs, while public warehouses have low fixed costs but potentially higher variable costs,

10.3 OWNSHIP The move towards contracting out warehousing means that the most common arrangement for warehousing is probably a mixture of private and public. An organization uses private warehouses for basic, core needs. a warehouse with enough capacity to meet peak demand will only work at full capacity for 75–85% of the time. So : private warehouse :75–85% of the time, public warehouses : the rest of the time.

USE THE PRIVATE AND PUBLIC TOGETHER

10.4 LAYOUT 10.4.1 General layout One of the most important decisions when running a warehouse is its layout. This describes the physical arrangement of storage racks, loading and unloading areas, equipment, offices, rooms, and all other facilities.

WHY Layout decisions are important ? (1) they require substantial investments of both money and effort, (2) they involve long-term commitments … (3) they have significant impaction the cost and efficiency of short-term operations.

10.4 LAYOUT WHAT are essential elements in a warehouse ? ●an arrival bay, or dock, where goods coming from suppliers are delivered, checked and sorted ● a storage area, where the goods are kept as stock ● a departure bay, or dock, where customers’ orders are assembled and sent out ● a material handling system, for moving goods around ● an information system, which records the location of all goods, arrivals from suppliers, departures to customers, and other relevant information..

10.4 LAYOUT

10.4 LAYOUT 10.4.2 Locating materials on shelves When there are thousands of items in store, small differences in the way they are arranged can give markedly different service and costs. The location of products of GuoGuang supermarket? Why did they design the layout like that?

10.5 MATERIALS HANDLING What is materials handling? MATERIALS HANDLING is concerned with the movement of materials for short distances generally within a warehouse, or between storage areas and transport.

10.5 MATERIALS HANDLING Aims of materials handling? moving materials around a warehouse as required moving materials quickly, reducing the number and length of movements increasing storage density, by reducing the amount of wasted space reducing costs, by using efficient operations making few mistakes, with efficient material management systems..

3 kind of warehouse for materials handling Manual warehouses Mechanized warehouses Automated warehouses

10.5 MATERIALS HANDLING Manual warehouses: People go around and pick items from the shelves, and put them into some sort of container for movement – like a supermarket trolley. Mechanized warehouses replace some of the muscle power of manual warehouses by machines. Typical examples of mechanized equipment are: reach trucks,(堆高机) order-picking machines（电动拣料机） forklift trucks（叉车） cranes,（起重机） towlines,（拖链） conveyors, （输送装置） tractors or trains（牵引机） carousels,（传送装置）

10.5 MATERIALS HANDLING

10.5 MATERIALS HANDLING 电动拣料机 叉车

10.5 MATERIALS HANDLING 传送装置 牵引机

10.5 MATERIALS HANDLING Automated warehouses ● storage areas that can be accessed by automatic equipment; these often use narrow aisles up to, say, 40 m tall to get a high density of materials and minimize the distances moved. ● equipment to move materials around the warehouse; these are usually automated guided vehicles (AGVs) which use guide wires in the floor, but might include conveyors, tractors, or a range of other moving equipment. ● equipment to automatically pick materials and put them into storage, including high-speed stacker cranes that can reach any point in the narrow aisles very quickly.

10.6 PACKAGE We have already mentioned pallets (the standard wooden trays about four feet square that materials are put on to ease movement) and containers (the 20- or 40-foot metal boxes that are used to move a huge variety of goods around the world). Collecting together materials into these standard packages is called unitization to form unit loads. It is much easier to move standard loads than it is to move a variety of different sizes and shapes. Another benefit of standard packages is that they can increase the density of storage.

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