1. Warehouse Space & Layout
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2. Lesson Objectives 1 2 By the end of this lesson, you will be able to:
Describe the different stacking methods 2
Use the stowage factors and calculate the stacking capacity in a warehouse

3. Three Aspects to Consider Organizational Elements
Warehouse Functions
Three Aspects to Consider
Structural Elements
Organizational Elements
Managerial Elements

4. Different Areas in the Warehouse
Work Area
Goods receipt
Storage
Picking/
Kitting
Goods Dispatch
Repacking/
Recondition

5. Stacking Methods

6. Stacking Methods

7. Stacking Methods Clean area before creating stack
Use good and clean pallets
Select stacking method
Identify space for spoiled and empty packaging
Identify space for reconditioning & repackaging damaged cargo
Use stack card

8. Stacking Methods
Unbonded Stacking
Bonded Stacking

9. Stacking Methods

10. Stacking Methods

11. Bad Practices
The stack should be built to give a firm bonded or interlocked stack
Do not stack so high that packages at the bottom are crushed or split
Do not throw or drop X
Remove projecting nails and splinters or the bottom bags may be torn and food spilt
Do not stack too close to the roof reducing ventilation and access
Do not stack close up to, or on top of, the roof beams so as to risk damaging the structure

12. Measurements – Commodities and WarehouseKG
Weight
(1000 KG) MT
SQM (M2)
Length X Width
Area
CBM (M3)
Length X Width X Height
Volume

13. Calculating Maximum Stack Capacity
Stack Characteristics: Height; Width; Length; Weight
Stowage Factor = Volume / Weight

14. Stowage factor
You have received a commodity in boxes with the following characteristics:
Height 15cm
Width 45cm
Length 60cm
Weight mtn
What is the stowage factor of this commodity?

15. Stacking Exercise Calculate the stack capacity for the following:
Rice in 50 kg bags with a stowage factor of 1.5cbm/MT
You have 70 pallets (size 1m x 1.2m)
Maximum storage height: 3m
B. What is the minimal number of pallets (1m x 1.2m) required to store 200 MT of a commodity that has a stowage factor of 2?
Maximum storage height: 2.5m
How many pallets will you need to square off the surface of the pallets?
What are the surface dimensions of the stack?

16. Stacking Exercise Answer (A)
Calculate the stack capacity for the following:
Rice in 50 kg bags with a stowage factor of 1.5cbm/MT
You have 70 pallets (size 1m x 1.2m)
Maximum storage height: 3m
Usable Surface Area = 70 x (1 x 1.2) = 84 sqm
Usable Volume = 84 x 3 = 252 cbm
Stack capacity = 252 /1.5 = 168 MT 

17. Stacking Exercise Answer (B)
B. What is the minimal number of pallets (1m x 1.2m) required to store 200 MT of a commodity that has a stowage factor of 2?
Maximum storage height: 2.5m
How many pallets will you need to square off the surface of the pallets?
Step 1: Required volume
(stack capacity) x (stowage factor) = (required volume) = 200 x 2 = 400 cbm
Step 2: Required surface
(required volume) / (max storage height) = (required surface) = 400 / 2.5 = 160 sqm
Step 3: Minimum number of pallets
(required surface) / (surface of pallet) = (minimum number of pallets) = 160 / 1.2 = 133.3
Step 4: Rounded quantity of pallets needed
Pallet dimensions = 1 x 1.2
We plan for 8 pallets (1 meter side) wide floor
The number of pallets per “column” is therefore = / 8 = 16.6 = 17 pallets
Number of pallets needed = 17 x 8 = 136 pallets ( 

18. Stacking Exercise Answer (B)
B. What is the minimal number of pallets (1m x 1.2m) required to store 200 MT of a commodity that has a stowage factor of 2?
What are the surface dimensions of the stack? ( 
Surface dimensions of a stack: 136 x 1.2 = sqm 

19. Stowage factors: References

20. Stock Location: Racked

21. Warehouse Capacity Considerations
Factors that affect warehouse storage capacity:
Type, characteristics and compatibility of cargo
Different storage requirements
Warehouse size and structure
Equipment
Remember
Available space = actual space + dispatches - receipts

22. Warehouse Layout Through-FLOW U-FLOW Truck Truck GOODS RECEIPT
STORAGE AREA
Truck
Truck
GOODS
RECEIPT
GOODS DESPATCH
PICKING
Truck
Truck
U-FLOW
STORAGE AREA
Truck
GOODS
RECEIPT
&
DESPATCH
PICKING
Truck

23. Lesson Recap 1 2 Questions: What are the different stacking methods?
What is a stowage factor and how to calculate the stacking capacity in a warehouse?

24. Questions
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