Raw Material Store or Warehouse - Design, Operation and Improvement (IE) - Articles and Case Studies

                               Pic Source: https://www.toyotaequipment.com/warehouse/mezzanine-systems/

For improving any operation in a process, industrial engineers need to have a good knowledge of alternatives at element level. Industrial engineering has to be carried out at element level, operation level, process level, facilities level and system level. System level productivity improvement is achieved by IE at the minute level to the macro level.

About Stores in "Manufacturing Facilities Design & Material Handling," International Edition.  

Prentice Hall

Author: Matthew P. Stephens / Fred E. Meyers   

Chapter 11 Material Handling Equipment 

Material handling equipment are grouped into four general categories.

Fixed-path or point-to-point equipment.  (Rail, conveyor)

Fixed-area material handling system (Jib crane)

Variable-path variable-area equipment. (All manual carts)

Auxiliary tools and equipment (pallets, skids, automatic data collection systems, and containers).

Equipments are listed  under the following sections.

1.  Receiving and shipping

2.  Stores

3.  Fabrication

4.  Assembly and paint

5.  Packout

6.  Warehousing

Receiving and Shipping 

Receiving and Shipping Docks 

Shipping Docks - Types

Flush docks

Drive-in docks

Drive-through docks

Finger docks

The four types represent over 90 percent of all docks used for trucks or railcars.

Dock Equipment 

Dock Door

An awning or porch over the rear of the trailer

Air curtains and plastic curtains

Extra lighting is often needed inside trailers, so portable lighting

Moving Equipment 

Hand Carts

Literally hundreds of different hand carts are available today. A few of the most

versatile and popular pieces of equipment follow:

1. Two-wheel hand truck

2. Pallet hand jack or pallet truck-hydraulic lift (also called just hand jacks)

3. Four-wheel hand carts 

4. Pallets

See for currently available carts

https://www.globalindustrial.com/t/carts-trucks

https://www.globalindustrial.com/t/material-handling

Fork Trucks

Fork truck attachments 

Attachments are available for moving paper rolls, carpet rolls, drums, trash, or many other parts and containers. . A boat marina uses extended forks to put motor boats into a storage rack. Oil, paint, scrap, and parts can be dumped by using a special dumping attachment.

Multipurpose Equipment

In an attempt to standardize material handling equipment, diversified multipurpose equipment must be given special consideration. 

A universal lift system. In the receiving and shipping areas, as well as in storage and warehousing, this material handling system can assist in loading and unloading trucks, and in lifting pallets, boxes, and other containers. It is capable of reaching high and hard-to-reach places, lifting or lowering loads well below the ground level, and performing a variety of other activities. The same equipment can also be quite useful on the factory floor. It can simplify the handling of dies and molds, handle large coils, and uncoil sheet metals.

Bridge cranes

Double gantry crane

Telescopic Conveyor 

Telescopic conveyors have several sections of conveyor that extend as needed.

Weight Scale 

Weight scales are valuable and useful receiving and shipping tools and they  are built into the material handling system.

New

AMRs in Warehouses

https://www.linkedin.com/pulse/modernizing-warehousing-amr-technology-practical-vincent-rijnaars  

Systems Required on Receiving and Shipping Docks 

Information and Coding Systems

1.  Part numbering systems that allow for identification of inventory

2.  Purchase order system authorizing the receiving of material. POs are received by stores and on their authority they receive material from suppliers. 

3.  Customer order system authorizing the shipment of material. (The sales orders to sent to stores/shipping by sales department)

4.  Bill of lading authorizing a trucking company to move material and to bill for their services. 

Stores 

“Stores” is the term used to describe the room where raw materials and supplies are held until they are needed by the operations department.

Storage Units 

Storage units can include the following:

1. Shelves store small parts. A typical shelving unit resembles a bookshelf with six 1 3 1 3 3-foot shelves one over the other.

2. Racks (pallet racks) are  used to store palletized material on pallet racks. A typical pallet rack is 9 feet wide with five tiers for a height of 22 feet. With two pallets per tier, five tiers high equals 10 pallets per pallet rack. 

3. Double deep pallet racks allow for stacking 20 pallets in a rack instead of 10 pallets. The density of storage is much better, and utilization of the building cube is improved. 

4. Portable racks are racks that fit over a pallet load of soft material. Another pallet is then set on top of this portable rack. Heights can be much higher without the danger of a stack falling over.

5. Mezzanines can be built over shelving areas to use the space over the shelves.  Slow-moving stock can be placed on the mezzanines.

6. Rolling shelves can function with one aisle in maybe 10 rows of shelves. Thus 9 aisles space is saved. The shelves are on wheels and tracks and can be moved to open up an aisle where no aisle exists now. Rolling shelves are popular in maintenance  stores (especially insurance spares) where daily issues are less.

7. Drawer storage units are another popular maintenance storage unit. Many small parts can be stored in a small area. One drawer may have 32 to 64 storage locations, and a 6-foot drawer unit could hold nearly 1,000 different parts. 

Stores Mobile Equipment 

Narrow aisle reach trucks are one of the better choices for maneuvering in storage

areas. Narrow aisle trucks can turn in narrow aisles, and the operator stands up.

Types of narrow aisle trucks:

1. Reach truck

2. Straddle truck. 

3. Side shifting lift trucks

Others

4. Maintenance carts.

5. Dollies and casters.

6. Maintenance tool crib.

7. Carousel storage and retrieval systems.

Systems Required for the Stores Department 

Locator System

Every location must have an address and the warehouse person must know how to reach any address without taking time to think.

Kitting System

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 https://precast.org/2010/05/raw-material-handling-and-storage/

https://www.aasturefrigeration.in/grocery-store-racks/

Improvement in the Inbound Logistics of the Tire Industry

Inês Catarina Marinho Cordeiro

Master’s Dissertation

Academic Supervision: Prof. Paulo Osswald

Mestrado Integrado em Engenharia Industrial e Gestão

2015-07-01

Improving the raw material warehouse at Borggårds Bruk AB

Adam Nordström

LINKÖPINGS UNIVERSITET | DEPARTMENT OF MANAGEMENT AND ENGINEERING

BACHELOR THESIS, 16 HP | BACHELOR OF SCIENCE – MECHANICAL ENGINEERING

HT 2016 | ISRN: LIU-IEI-TEK-G--16/01126—SE

Suggestion of Raw Material Warehouse Layout Improvement Using ClassBased Storage Method (case study of PT. XYZ)

Article  in  IOP Conference Series Materials Science and Engineering · December 2020

Optimizing Warehouse and Inventory by FSN Analysis: Case Study of ZZZ

Printed Circuit Board Manufacturing Company

Conference Paper · January 2019

Abstract

This research aimed to optimize the warehouse and inventory in case study of ZZZ printed 

circuit board manufacturing company at locations P7 by FSN analysis and rearranged the 

warehouse layout. The result was, after improvement, the storage time was reduced from 

37.47 to 27.07 minutes (27.76%), the operator was reduced from 2 to 1 person (50%), 

Average volume of raw material that are kept outside the warehouse was reduced from 14.40

to 11.16 cubic meters (22.50%), Average distance to storage the raw material was reduced 

from 70.24 to 55.84 meters (20.50%), and the process to storage the raw material was 

reduced from 9 to 6 steps (33.33%),

 https://www.researchgate.net/publication/331976635

Ud. 14.8.2023

pub. 6.10.2021