Showing posts with label Storage and Warehousing. Show all posts
Showing posts with label Storage and Warehousing. Show all posts

Thursday, August 28, 2025

Logistics System Industrial Engineering

In the flow process chart framework, the operations transport, permanent storage and temporary storage or delays form the logistic system. Processing operations and inspection form the manufacturing system. The logistic system is also subjected to industrial engineering as part of operation industrial engineering.

In the supply chain system also logistics system is there. It is also needs industrial engineering.


What is a logistics department?

A logistics department is the company division charged with ensuring that goods and services reach customers or production lines as efficiently as possible and at the expected time.


Functions of the logistics department


Supply and procurement management


The logistics department is tasked with managing product availability in the warehouse and streamlining goods receipt, storage and dispatch.


Order fulfilment and shipping  - On the Sales side





Cost optimisation

By thoroughly analysing supply chain activities, the logistics department can implement changes aimed at reducing operational expenses without compromising service quality.


Planning and data analysis


Distribution and transport


Supplier and Receipt quality management


Continuous improvement and innovation

https://www.mecalux.com/blog/logistics-department


Software for Logistics: 8 Major Types and Their Benefits

https://www.digiteum.com/8-major-types-of-software-for-logistics/


Driving Savings via Inbound Logistics Network Design

MIT Center for Transportation & Logistics

By: Geraldine Mae P. Felicio and Deepika Sharma Advisor: Dr. Sergio Alex Caballero 

Summary: In this study, we studied inbound supply network for a CPG company to find opportunities to optimize both cost and visibility. This report studies three design changes to the CPG company’s current inbound supply network, namely: 1) Consolidated Inbound and Outbound Deliveries, 2) Develop a Supplier Village and relocate supplier firms in that village, and 3) Reallocate Raw materials and Packing Materials inventory to Finished Good inventory site.  

Warehouse Industrial Engineering - Warehouse Efficiency Improvement - Bibliography

Warehouse and Factory Material Handling Equipment and Systems - Manufacturers and Systems

Smart Warehouse - Industry 4.0 Warehouse - Warehouse 4.0

Warehouse Productivity - Efficiency Improvement

https://nraoiekc.blogspot.com/2016/10/warehouse-productivity-efficiency.html


Knowledge Base for Process Productivity Improvement - News - Information for

Related Content


 LIE Case Study

https://www.wagnerlogistics.com/who-we-are/case-studies/35-industrial-engineering


 Department of Industrial and Systems Engineering, University at Buffalo - Transportation and Logistics ISE

Transportation and logistics ISE research 


India - Transport and Logistics Services - Growth, Productivity and Quality - Seminar 21 January 2021.

Logistics Industrial Engineering Intern

Date:  Jun 16, 2021

Brand:  Oakley

Location:  Foothill Ranch, CA, US, 92610

Requisition ID: 365441 

Store #: O00116 Human Resources - 1ICON FHR 

Position:Seasonal/Temporary

Total Rewards: Benefits/Incentive Information

Oakley.  Designed to push the boundaries of performance.  From advanced eyewear technology to apparel innovation, Oakley sets itself apart from the rest. Backed by the power of Luxottica, our athletes and customers expect the best in sports performance and Oakley employees help to fuel this drive


GENERAL FUNCTION


Oakley. Designed to push the boundaries of performance.  From advanced eyewear technology to apparel innovation, Oakley sets itself apart from the rest. Backed by the power of Luxottica, our athletes and customers expect the best in sports performance and Oakley employees help to fuel this drive. 


The Oakley Summer Internship Program is a 10-week immersion into the Oakley brand. It’s a project-based internship where you will have the opportunity to learn, collaborate, and contribute to business success by working on priority projects. At Oakley, we love what we do! We are looking for students who share our passion and can turn their passion into dedication and focus to deliver great results.


See possibilities at Oakley by joining us as a summer intern in a Logistics Industrial Engineering related function.


 


MAJOR DUTIES AND RESPONSIBILITIES


Identities opportunities for process improvements and develops projects to improve

Streamlines operations to improve services to our customers.

Works cross functionally with key stakeholders across the Luxottica organization.

 


 BASIC QUALIFICATIONS


Currently pursuing a degree in Industrial Engineering, Supply Chain Management, Logistics or related major

Self-starter and driven to succeed

Previous internship experience in engineering, logistics or continuous improvement

Minimum 3.0 GPA

Must be authorized to work in the U.S.

Available the full 10-week program, 40 hours per week

Interest in corporate finance & accounting.

Ability to multi-task and thrive in a fast-paced, dynamic environment

 

 PREFERRED QUALIFICATIONS

Study abroad or international exposure

Demonstrate leadership ability and relationship building skills

Upon request and consistent with applicable laws, Luxottica will provide reasonable accommodations to individuals with disabilities who need assistance in the application and hiring process.  To request a reasonable accommodation, please call the Luxottica Ethics Compliance Hotline at 1-888-887-3348 or e-mail HRCompliance@luxotticaretail.com (be sure to provide your name and contact information for either option so that we may follow up in a timely manner). 

https://jobs.luxottica.com/LRNA/job/Foothill-Ranch-Logistics-Industrial-Engineering-Intern-CA-92610/667986101/

LIE Minor

https://engineering.kennesaw.edu/systems-industrial/degrees/minor-logistics.php



Logistcs Companies


TCI Express India

https://www.tciexpress.in/express-services.aspx



Ud 28.8.2025  16.1.2023, 24.6.2021




Tuesday, October 8, 2024

News - Information for Storage/Warehousing Operation Industrial Engineering Analysis


Process Improvement using engineering knowledge to reduce cost through increasing productivity of machines and men by reducing machine time and man time is the main activity of industrial engineering.

Many other disciplines help industrial engineers to achieve their objectives. But the main discipline that is the foundation for IE is engineering of products and processes.

Industrial engineer analyzes each process into its ultimate, simple elements, and compares each of these simplest steps or processes with an ideal or perfect condition and modifies the element appropriately. - F.W. Taylor - Hugo Diemer.

Prof. Hugo Diemer  - Taylor's Industrial Engineering

https://nraoiekc.blogspot.com/2020/05/prof-hugo-diemer-taylors-industrial.html





Storage and Warehouse System - Process Improvement - Flow Process Chart Based Industrial Engineering - Module Lessons




Warehouse Industrial Engineering

Book: Warehouse Science


Flow Process Chart - Value-Adding Operation - Inspection - Transport - Temporary Delay - Storage - Information

Information added in flow process chart steps  by Narayana Rao K.V.S.S. (1 July 2020)

There is a three way break up of time in a process.

Value added activity time + Non-value added activity time + No value added time.

Cost is incurred all the time. Time reduction is cost reduction if resources are same. (Narayana Rao, 19 July 2021)



Knowledge Base for Process Productivity Improvement - News - Information for

________________________________________________________________________

Do it. It is Real Engineering. Industrial Engineering is Engineering Primarily.

Find 5 new engineering developments every day in elements related to facilities, products and processes in your organization and assess their use for industrial engineering. 
Best Practices in #IndustrialEngineering 


2024
Essential Warehouse Equipment List - Types and Benefits.

Modula Vertical Storage Solutions – For Every Operational Need

2023

Warehouse Storage Rack Manufacturer - India


RFID in the Warehouse: Driving Fulfilment Efficiency
With RFID technology deployed, retailers can optimize their entire supply chain operations and drive increased fulfillment efficiency, benefiting all stakeholders involved.
August 8, 2023


Drone based solution for inventory taking and tracking.

Drone- and sensor-based solution for autonomous stocktaking and inventory

✅ using mapping data
✅ LED lights for dark aisles
✅ scans 12 pallets every 110 seconds
✅ fully charged in 12 hours

Tracking every pallets' position with laser precision.

The ground robot continually monitors its 2D position within the digital map of the site, whilst simultaneously monitoring the vertical position (height) of the drone in relation to the height of each shelf + ensuring that every barcode detected is mapped precisely to the physical rack position in which it was found.
  



2022

About Receiving Materials



https://www.compliancequest.com/blog/automation-inspection-raw-material-critical/

https://www.willstransfer.com/blog/raw-material-storage/

https://v2020eresource.org/content/files/storage.htm

https://www.dematic.com/en-au/products/receiving/

https://www.mecalux.com/blog/phases-goods-processing



Storage Strategies – Stacking Options
February 11, 2020 by Christoph Roser


Michael Miller Fabrics Warehouse Tour | Bolts, Bundles and Fabric Galore! - Interesting.
https://www.youtube.com/watch?v=Jlx89TLZTWY

Sensors and Mobile Platforms: The Eyes and Ears of the Modern Warehouse
January 26, 2022
Equipping autonomous and semi-autonomous vehicles with intelligent sensor technology, to develop safe, efficient distribution (DC) and fulfillment center (FC) operations
With automation making a big mark on the modern warehouse or DC, automatic guided vehicles (AGVs) and mobile collaborative robots continue to make their way into the fulfillment environment, where 34% and 20% (respectively) of companies are already using automated equipment to run their logistics operations.
https://sickusablog.com/sensors-mobile-platforms-eyes-ears-modern-warehouse/

https://www.signode.com/en-us/productslist/asrs/

 "Comprehensive Methodology for the Design Configuration and Operational Control
of Shuttle-based Storage and Retrieval Systems," by Donghuang Li, PhD 

Performance evaluation of shuttle-based storage and retrieval systems using discrete-time queueing network models, Martin EPP, 2017 Doctoral thesis

https://www.researchgate.net/publication/273380170_Simulation_Analysis_of_Shuttle_Based_Storage_and_Retrieval_Systems    (2015)





Why did Dell choose Geek+’s picking solutions to upgrade its warehouse?
Geek+ innovatively integrated the rapid visual inventory feature in the ‘goods to person’ picking system, improving the inventory management

Pesmel
The Material Flow How® Company
We at Pesmel design and deliver automated material flow solutions in industrial handling, packing, storing and logistics. Our focus is on increasing the overall efficiency of our customers’ operations through the benefits of ensured quality and accuracy of deliveries, improved space efficiency, work safety and shorter turnaround times.
https://www.linkedin.com/company/pesmel/
https://pesmel.com/

What Is The Best Type Of Flooring For A Warehouse?
Concrete Alone Isn’t Up To The Job.
Warehouse Epoxy Flooring.
To find out more about our Food Grade heavy-duty polyurethane floor coating and other industrial floor coatings then head to our website today.

Using Bin Sequencing for NetSuite Bin Management
RF-SMART  @rfsmart
If your business is growing, bin sequencing can help you designate an efficient pick path without having to re-label your entire facility.
https://www.youtube.com/watch?v=EEeNtONElrw

Warehouse Types in the 21st Century
Stein Service Supply @SteinService
https://steinservicesupply.com/warehouse-types-in-the-21st-century/

Scanners for Warehouses

Warehouse Security: Choosing The Right Warehouse Locks
United Locksmith @LocksmithUnited
https://unitedlocksmith.net/blog/warehouse-security-choosing-the-right-warehouse-locks

An automated parcel dimensioning system plays a significant role in managing all the warehousing operations.
The size plays a massive role in the warehouse vertical, right from the market size to estimating a delivery timeframe depends on the parcel size to the customers’ doorstep.
https://www.linkedin.com/posts/yuvarajganesanvisailabs_how-size-matters-in-the-world-of-automated-activity-6801183058813952000-2_QC/

2021

Maximizing Profits in a Warehouse and Distribution Business - PDF
by A Darmesh · 2021 

A Guide To Organising Warehouse Storage: From Industrial Shelving and Storage Cabinets To The Floorplan and More Articles on Warehousing

India - Top 10 Industrial Storage System Manufacturers - 2021

Types of Industrial Racking for the Warehouse: Classification and characteristics






Inside Amazon's Smart Warehouse
30 Nov 2020
_______________________


https://www.youtube.com/watch?v=IMPbKVb8y8s
________________________



DATE: 6/29/2020

Using Robotics as a Service to Increase Productivity in Warehouses
SCOTT SHAW
Supply Chain Services Leader
https://clarkstonconsulting.com/insights/using-robotics-as-a-service-to-increase-productivity-in-warehouses/

MAY 21, 2020
Tips for Using Automated Warehousing Better.
Four tips for making the most of an automated warehouse.
David Madden
https://www.newequipment.com/plant-operations/article/21132049/tips-for-using-automated-warehousing-better


Motion Waste: The Silent Killer of Warehouse Productivity
January 28, 2020
https://www.logiwa.com/blog/motion-waste


Warehouse Order-Picking with AR Smart Glasses
_____________

9 March 2020
Tech Mahindra
_____________


Tips on Improving Warehouse Productivity
MH&L Staff
FEB 27, 2017
https://www.mhlnews.com/technology-automation/article/22053090/tips-on-improving-warehouse-productivity



Mannington Carpet Products Master Distribution Center Design - Productivity Benefit 


Planning and design of a newly acquired retrofitted facility to serve as a master distribution center

Mannington recently acquired an existing manufacturing facilty site  in Calhoun, Georgia and converted into a master distribution center. The redesigned facility is to receive, warehouse, pick and ship the following materials:

Carpet products including modular (palletized carpet tile), and 6’ and 12’ broadloom carpet (rolls), all currently manufactured in Calhoun at the manufacturing plant located approximately 1 mile away from the new building. Several products are arrive as case goods to be stored on pallets.

The final design provided flexible storage solutions, focusing on maximizing cube utilization in comparison to the utilization of space in existing facilities. New design allowed for use of smaller footprint. The space efficient design resulted in 70K sqft of additional warehousing capacity. The project was completed on-time.

The JSC team (consultant) surveyed multiple existing Mannington operations and completed a detailed storage data analysis. Then,  the JSC specialist identified opportunities to conserve space and increase storage utilization. The team achieved both through exhaustive data analysis, space modeling and the integration of multiple storage solutions. All of which were specified in the appropriate quantities based on product handling attributes and velocity.

Johnson Stephens Consulting
a division of Hy-Tek Integrated Systems

(678) 842-9114
100 Hartsfield Centre Parkway,
Suite 520
Atlanta, GA 30354
info@JohnsonStephens.com
https://johnsonstephens.com/case-studies/mannington/

August 5, 2020
Atlanta, GA – Johnson Stephens Consulting, a division of Hy-Tek Integrated Systems, has been recognized by Supply Chain Brain in the 2020 list of “100 Great Supply Chain Partners." To be included in this list, a vendor must be nominated by satisfied customers. It’s the true test of whether those bold advertising claims prove out in the real world.
https://johnsonstephens.com/media/jsc-named-to-supply-chain-brain-100-great-supply-chain-partners/


Modern Warehouse Technology
13 March 2020
______________________


https://www.youtube.com/watch?v=smilviq8tv0
______________________

Updated on 24.8.2023,  23.3.2022,  7 Jan 2022,  27 May 2021, 22 Feb 2021,     22 August 2020,
5 July 2020

Monday, October 7, 2024

Automated Storage and Warehousing - Storage Operation Improvement in Engineering Processes

Storage and Warehouse System - Process Improvement - Flow Process Chart Based Industrial Engineering - Module Lessons

Lesson No.   - Lesson Topic



Industrial Engineering - Role of Engineering, Mechanization and Automation


In process improvement study or projects, to do a task in the most productive manner, the most efficient manual method (best manual method), best mechanized method and best automation method are to be compared and the most productive method has to be employed. This comparison has to be done at element or suboperation level.

Source: Book: Motion and Time Study: Design and Measurement of Work, Ralph M. Barnes, 7th Edition, Chapter 18. Motion Study, Mechanization, and Automation.

Jidoka - Automation and Mechanization - Process Engineering and Industrial Engineering in Toyota Production System

Jidoka, a pillar of Toyota Production Systems advocates automation with human touch in all operations of a process to increase productivity of operators as well as that of total systems.

  

Automation of Operations in Flow Process Chart








In engineering processes, storage is an important operation. There is cost associated with storage. As a part of process improvement, requirement for storage needs to be minimized and also unit cost of storage has to be reduced using methods similar to those used for reducing costs of material processing, inspecting and transporting. Automation is an approach to reduce total cost of storage.

Automated storage systems are available that reduce the cost in certain storage applications. The level of automation varies. In less-automated systems, a human operator is required in each storage/retrieval transaction. In highly automated systems, loads are entered or retrieved under computer control, with  human participation limited data input  to the computer. 

Automated storage systems are available in two general forms: (1) automated storage/retrieval systems and (2) carousel storage systems.

An automated storage and retrieval  system (AS/RS) is a storage system that performs storage and retrieval operations  under a defined degree of automation.  At the most sophisticated level. the operations are totally automated, computer controlled, and they respond to the instructions of factory and warehouse management systems. At lower levels of automation,  human workers are involved in every storage and retrieval transaction with some automation in storage and retrieval actions.  

An AS/RS consists of one or more storage aisles that are each serviced by a storage/retrieval (S/R) machine. (The S/R machines are sometimes referred to as cranes.)The aisles are located between  storage racks for holding the stored materials. The S/R machines  deliver materials to the storage racks and retrieve materials from the racks. Each AS/RS aisle has one or more input/output stations where materials are delivered into the storage system or moved out of the system. The input/output stations are called pickup-and-deposit (P&D) stations in AS/RS terminology.  P&D stations can be manually operated or interfaced to automated handling system such as a conveyor or an AGV. 

__________________________


https://www.youtube.com/watch?v=YYdgLAlogpY

__________________________

AS/RS Types and Applications. 

• Unit load AS/RS. The unit load AS/RS is typically a large automated system designed to handle unit loads stored on pallets or in other standard containers. 

 Deep-lane AS/RS. The deep-lane AS/RS is a high-density unit load storage system that is appropriate when large quantities of stock are stored, but the number of SKUs  is relatively small.  Each rack is designed for "flow-through," with input on one side and output on the other side. Loads are picked from one side of the rack by an SIR-type machine designed for retrieval, and another machine is used on the entry side of the rack for load input.

• Miniload AS/RS. This storage system is used to handle small loads (individual parts or supplies) that are contained in bins or drawers in the storage system. The SIR machine is designed to retrieve the bin and deliver it to a P&D station at the end of the aisle so that individual items can be withdrawn from the bins. The P&D station is usually operated by a human worker. The bin or drawer must then be returned to its location in the system. A miniload AS/R system is generally smaller than a unit load AS/RS and is often enclosed for security of the items stored.

• Man-an-board AS/RS A man-an-board (also called man-aboard) storage/retrieval system represents an alternative approach to the problem of retrieving individual items from storage. In this system, a human operator rides on the carriage of the SIR machine. The man picks individual items.  This offers an opportunity to increase system throughput

• Automated item retrieval system. These storage systems  retrieve  individual items or small product cartons stored in lanes.  To retrieve an item. it is pushed from its lane and it drops onto a conveyor for delivery to the pickup station. The supply of items in each lane is periodically replenished, usually from the rear of the system so that there is  first-in/first-out delivery. 


____________________________


https://www.youtube.com/watch?v=dIn0GWlYDdc

____________________________




• Vertical lift storage modules (VLSM or/ VL-AS/RS).   Vertical lift storage modules have vertical aisles, some with heights of 10 m (30 ft) or more, save floor space in the factories.

_____________


https://www.youtube.com/watch?v=lWAgKvk5xC8

_____________


Work-in-process (WIP) storage in AS/RS. 

Work-in-process (WIP) storage is also being kept in AS/RS. 

 It is not unusual for a plant engaged in batch production to have hundreds of orders in progress simultaneously, all of which represent work-in-process. Automated storage systems help to store WIP neatly and efficiently. They deliver the jobs according to the priority decided by production schedulers and bring discipline in the shop.  

More detailed description of AS/RS system for WIP Storage

Work-in-Progress Handling

Solving Challenges: Space Shortages, Production Inefficiencies, Labor Shortages, and Workplace Safety. Installing an AS/RS as an Inter-Process Buffer Solves Issues of Space, Labor, Safety, and Efficiency

By introducing a buffer system that combines an automated storage and retrieval system (AS/RS) with transport equipment such as shuttle carts or AGVs, it is possible to solve the above four problems and increase operational efficiency and safety.



• Support of just-in-time delivery. Some plants have installed automated storage systems as storage buffers for incoming materials. 

• Kitting of parts for assembly. The storage system is used to store components for assembly of products or subassemblies. When an order is received, the required components are retrieved, collected into kits (tote pans), and delivered to the production floor for assembly.

• Compatible with automatic identification systems. Automated storage systems can be readily interfaced with automatic identification devices such as bar code readers. This allows loads to be stored and retrieved without human operators to identify the loads.

• Computer control and tracking of materials. Combined with automatic identification, an automated WIP storage system permits the location and status of work-in-process to be known.

• Support of factory-wide automation. Automated storage system becomes an important subsystem in a fully automated factory.

Components and Operating Features of an AS/RS. 

 (1) storage structure, 

(2) S/R machine, 

(3) storage modules  and 

(4) one or more pickup-and-deposit stations. 

(5) control system

The S/R machine consists of a rigid mast on which is mounted a rail system for vertical motion of the carriage. The base of the mast has wheels to permit horizontal travel along a rail system that runs the length of the aisle. 

The carriage includes a shuttle mechanism to move loads into and from their storage compartments and to receive the load from the P&D station. 

To accomplish the desired motions of the S/R machine, three drive systems are required: horizontal movement of the mast. vertical movement of the carriage, and shuttle transfer between the carriage and a storage compartment. Modem S/R machines are available with horizontal speeds up to 200 m/min (600 ft/min) along the aisle and vertical or lift speeds up to around 50 m/min(150 ft/min).The speeds determine the time required for completing a task.

The storage modules  include pallets. steel wire baskets and containers, plastic tote pans, and special drawers. 

The pick -and-deposit station is where loads are transferred into and out of the AS/RS.

They are generally located at the end of the aisles for access by the external handling system that brings loads to the AS/RS and takes loads away. 

Computer controls and programmable logic controllers are used to determine the required location and guide the SIR machine to its destination. The automatic controls can be superseded or supplemented by manual controls when required under emergency conditions or more frequently for man-an-board operation of the machine.

Carousel Storage Systems

A carousel storage system consists of a series of bins or baskets suspended from an overhead chain conveyor that revolves around a long oval rail system. The chain conveyor positions required bins at the load/unload station.   Carousels are automated by using transfer mechanisms at the load/unload station to move loads into and from the carousel.

Carousel Technology. Carousels can be classified as horizontal or vertical. The more common is horizontal configuration. It comes in sizes, ranging between 3 m (10ft) and 30 m (100 ft) in length. 

The structure of a horizontal carousel storage system consists of welded steel framework that supports the oval rail system. The carousel can be either an overhead system (called a top-driven unit) or a floor-mounted system (called a bottom-driven unit). In the top-driven unit. there is an overhead trolley system. The bins are suspended from the trolleys. In the bottom driven unit,  the trolley system rides on a rail in the base. This provides more load-carrying capacity for the carousel storage system.  Bin widths range from about 50 to 75 cm (20 to 30 in), and depths are up to about 55 cm (22 in). Heights of horizontal carousels are typically 1.8-2.4 m (6-8 ft). Bins are made of steel wire to increase operator visibility.

Vertical carousels are constructed to operate around a vertical conveyor loop. They occupy much less floor space than the horizontal configuration. 

_________________________


https://www.youtube.com/watch?v=KNR_Dot7XG4

_________________________

Manual foot pedal control allows the operator at the pick station to rotate the carousel in either direction to the desired bin position. Hand control involves use of a hand-operated switch that is mounted on an arm projecting from the carousel frame within easy reach of the operator. Again, bidirectional control is the usual mode of operation. Keyboard control permits a greater variety of control features.   The operator can enter the desired bin position, and the carousel delivers the bin to the pick station.

Computer control increases  automation of the carousel and provides for management of the inventory records.  

Carousel Applications. Carousel storage systems  are  an attractive alternative to a miniload AS/RS in manufacturing operations where its relatively low cost, versatility, and high reliability are recognized. Storage and retrieval operations can be efficiently accomplished using carousels when individual items must be selected from groups of items in storage. This kind of procedure is common in order-picking of tools in a tool-room, raw materials in a stockroom, service parts or other items in a wholesale firm, and work-in-process in a factory. Carousel storage systems often compete with automated storage and retrieval systems for applications where work-in-process is to be temporarily stored. 


Automated Storage and Warehousing - AS/RS -  Case Studies


RoboVault introduces a state-of-the-art automated self storage facility

Westfalia Technologies, Inc. was commissioned to develop a state-of-the-art automated self storage facility in Ft. Lauderdale Fla., RoboVault. This new venture was also a new era in the self storage industry which introduced Automated Storage and Retrieval Systems (AS/RS), typically seen in the warehouse and manufacturing plant.



C.F. Roark Installs an ASRS for Tools & Dies - Case Study
17 Oct 2013
Bastian Solutions
Roark, a contract manufacturer for the aerospace industry, came to us needing a better, more efficient way to store and retrieve their tools and dies.  We installed this automated storage and retrieval solution.




News - More Information and Articles Automated Storage and Warehousing - Storage Operation Improvement 

2022

Automated Material Handling in Warehouse of Pitman Creek, Kentucky.

Benefit: a 250% improvement in picking efficiency.

January 20, 2022

The pickers were allotted to zones. For any order, the picker picks items in his zone and puts them in a totebox. Inventory in the zone was slotted such  the most frequently picked items were stored nearest the conveyor. An order selector could pick 72% of most orders in the four rows nearest the conveyor and complete 97% in the eight rows nearest the conveyor.

Further, a recirculating conveyor is used as buffer storage until all of the totes needed for an order are ready and can be sent to a packing station. The packing section will receive all totes at the same time and will do the packing.



2021 Warehouse and DC Operations Survey: Automation Initiatives

By Roberto Michel · November 8, 2021


Material Handling Systems in Use.

Forklifts
Push Carts
Conveyors
Vertical Lift Modules
Palletizer
Sorters
Robots/Articulating Arms
AGVs/Autonomous Mobile Robots
Carousels
Others


Customers are demanding faster delivery and more accurate inventory management. Are you prepared to rise to the occasion? Failure to adapt could be more expensive than incorporating warehouse automation systems.

AMR'S AND AGV'S MAY BE THE ANSWER TO THIS PRESSING CHALLENGE.


Automated Storage & Retrieval System (AS/RS) detailed explanation: types & benefits
August 26, 2021
Ajay Kumar
Robotics | Warehouse automation ( Conveyors, AS/RS, Picking, Dock, Racking & Shelving)


Warehouse Automaton detailed explanation: Types & benefits
August 6, 2021
Ajay Kumar
Robotics | Warehouse automation ( Conveyors, AS/RS, Picking, Dock, Racking & Shelving)


Warehouse Automation Explained: Types, Benefits & Best Practices
Abby JenkinsAbby Jenkins | Product Marketing Manager
December 10, 2020






Ud   7.10.2024, 7.10.2022,  9.11.2021, 19.10.2021, 7.10.2021
Pub 22.12.2020






Warehouse and Storage Facilities - Principles for Design and Options

 In industrial engineering, in a process productivity and cost analysis, warehouse and storage activities are also recorded in the process chart and analyzed for productivity improvement.


To improve any activity from any perspective, the designers have to know the principles of design and options available to include in the design.


https://www.google.com/search?q=warehouse+-++Principles+for+Design+and+Options


https://www.linkedin.com/pulse/10-proven-principles-best-warehouse-design-operation-rob-o-byrne/



Effective Design and Management of a Production-Based Warehouse: Organizing and Optimizing Different Sections

Managing a production-based warehouse involves a complex set of tasks and responsibilities, requiring careful organization, efficient processes, and a keen eye for detail. The goal is to ensure that all warehouse operations support the overall production goals, maintaining a seamless flow of materials, products, and information. Here’s a comprehensive guide on how to effectively manage a production-based warehouse and optimize its different sections.

https://prod-action.com/2024/01/10/define-world-best-it-solution-technology/





Ud. 7.10.2024

Pub. 22.6.2024



Sunday, October 6, 2024

Warehouse Processes

Storage and Warehouse System - Process Improvement - Flow Process Chart Based Industrial Engineering - Module Lessons



Warehouse Science Book

https://www2.isye.gatech.edu/~jjb/wh/book/editions/wh-sci-0.96.pdf



Warehouse Processes


Warehouses deal with numerous processes.  They help in managing the order rates and in cost- control. They are also the main activities that take place at a warehouse. Companies gain an edge over their competitors as efficient warehousing services always mean better order fulfilment and, in turn, customer satisfaction. 

1. Receiving

The first process that takes place in a warehouse is the receiving. As the name suggests, this is the step in which the product reaches the warehouse. The workers are supposed to cross-check the items that have been received and ensure that they are of acceptable quality and quantity. It may be stored in the inventory(for the long-term) or the main storage area(for the short-term) based on its requirement. 

Once the inbound items are received, it is the responsibility of the warehouse to keep it safe until the order goes for dispatch. 

Warehouses must ensure that there is no overcrowding of goods. 



Procedure for raw material receipt - Illustration


Procedure

Warehouse head or designee shall receive communication from supply chain department about the supply of raw material to the manufacturing facility.

On arrival  of the vehicle, security department of the facility shall inform to warehouse supervisor about the arrival of material. Security person shall collect the documents from the transporter and handover to the warehouse department. The documents shall be material invoice, certificate of analysis, Material Safety Data Sheet (MSDS).

The documents received from the supplier should possess the purchase order number on the document to ensure receipt of correct material at the time of receipt.

On receipt of the documents, warehouse person shall check the documents against purchase order,   vendor approval status and supplier approval status  in the Electronic Material Management System

Material manufacturer’s address on Certificate of Analysis (CoA), and container label must be matched with approved vendor list. While checking the address, company name, plot number, address, street name, pin code and all other minute details should be checked and ensure compliance.

In case of material manufacturer as well as supplier, details of manufacturer as well as supplier with address must have to be in line with the approved list in the received documents.

In case of material manufacturer’s address is not mentioned on CoA or container, batch number on CoA shall be verified against batch number available on container label. Batch number should be matched with each other and full address in-line with approved vendor list must have to be match with either CoA or material container label.

Once all documents found compliant, warehouse personnel shall allow the vehicle to enter in the factory premises. At a time only one vehicle shall be attended by warehouse person. The vehicle shall be taken to the receipt bay. It should be placed in such a way that vehicle should not be open in open roof.

Vehicle should be verified for its cleanliness, smell and other kind of materials in the vehicle.

Vehicle should available in clean condition; it should not have any abnormal smell and condition, it should not have received with any poisonous chemical, poisons, insecticides, food material etc. vehicle inside condition should be dry.

Material shall be unloaded on the receipt bay. In case of multiple batches received, it shall be unloaded batch wise on clean pallets.

After unloading the material, warehouse personnel shall de-dust the materials outer surface of each container with vacuum cleaner or clean dry duster.

Material pallet should be verified at the time of receipt. It has to ensure that the wooden pallet should not have preservative treatment of halogenated-phenolic compound (Reference https://www.fda.gov/drugs/guidances-drugs/questions-and-answers-current-good-manufacturing-practices-buildings-and-facilities). Pallet certificate must have to be acquired at the time of receipt ensuring above requirement.

The received material shall be transfer on the company’s  pallets. Material pallet shall be taken into the material movement air lock. Before taking the material into the airlock and while opening the door of airlock, air curtain shall on to break air movement from outer side to inside and to prevent the contamination.

Material shall be ensured as per material receipt checklist. The checklist shall contain following information:

Purchase Order

Certificate of analysis from the manufacturer, Approved Vendor and supplier

MSDS

Storage condition of material

Cleanliness of vehicle

Smell of vehicle for any abnormality

Spillage of material in the vehicle

Possibility of Material contamination because of any other means.

Material should not accompany food, harmful chemical such as pesticides, controlled substance etc.

Integrity of the seal

Seal number of container should be matched with serial numbers provided by manufacturer when they have dispatched the material from their facility

The integrity of the containers

Container physical condition – material container should not have any damage

Pharmacopoeial grade

Material labeled for complete address of manufacturer

Data logger must have received with cold chain materials

Pallet certificate to ensure that the pallets are not treated with halogenated-phenolic compound

Pre-sterilized material must have to be verified for sterilization evidence as applicable i.e. Gamma eradiation evidence, ETO (Ethylene oxide) etc.

Weigh the material for gross weight. The weight of gross weight should not be differing from 2.5 % of the weight specified on the container.

Once the material is taken into the air lock, air clock shall be closed. Material shall be de-dusted using vacuum cleaner or lint free duster.

When receipt of material any discrepancy with respect to above point is noted, record the same in the checklist. Inform to the warehouse head and Quality Assurance (QA) person.

In case of condition of material is not acceptable, QA person shall reject the material by affixing the rejected label on the specific container or entire consignment depending on the situation.

The identified defect can be classified as follows:

Critical Defects: Damaged container and material is spilled, material exposed to the environment, missing seal, less than acceptable tolerance.

Major Defects: Outer container is damaged or deformed but inner bag found intact.

Minor Defects: Containers with dent surface but integrity is maintained.

Record the rejection in material discrepancy note and it shall be signed by warehouse and QA person. Depending on the types of defect, material can be returned to vendor after completion of documentation.

In case of material is rejected and cannot be sent to manufacturer back immediately, it shall be stored at appropriate storage condition as per label claim.

When receipt of material, if any label found torn but information is intact, the label can be laminated with lamination film to keep the material label information intact.

On satisfactory verification of material, material inward entry shall be done in the material management software.

In case of material outer container found damaged but inner container is intact, inner bag shall be transfer to new similar container (material of construction and specification of the container should be same. Label from original container should also be affixed to new container.

Once the material inward done in the material management software, it shall be labeled with quarantine labels and placed at designated location.

While entering the information in the material management software, care should be taken to ensure that correct information is entered and second person shall verify the information for its accuracy.

Batch number and expiry date are critical information for the traceability and validity of the material.

Expiry date shall be entered in the system as follows:

Allocate the expiry date based on date specified on CoA and container label.

If the expiry date is not specified and other terminology is used by material manufacturer such as valid up to, best before, use before, this information shall be considered as expiry period of the material.

In case if the container does not have expiry period but re-test period only, the retest period shall be considered as expiry. In such cases, the expiry date can be extended when manufacture provide supporting stability data to support shelf life extension. Such cases should be handled through appropriate QMS tool.

In case of cold chain material, it is required to ensure that material received along with data logger. The data shall be downloaded and reviewed for any excursion. If temperature excursion is noted, the event shall be investigated and recorded. Impact of excursion shall be evaluated before it is release for use.

While receipt and transfer of material which is sensitive to static electricity/ static charge, adequate measure such as earthling of container should be done before material handling.

In case of any exposure of material to human, instruction provided in the MSDS should be followed till the medical help is arrived.

2. Put-Away

Put-away is what takes place after the receipt. The received products are supposed to be put in a storage place, and this process is called put-away. It is done by the put-away staff who receive a notification about this requirement on the receipt of the inflow. Proper planning of this process helps in the appropriate use of the storage space and the safety of the workers.  Only after the goods are stored in the correct location and accounted for, the process is considered complete. The size and weight are considered primarily while deciding the storage place. 

Slotting and space management systems are softwares that reduce manual hard work by automatically assigning storage spaces to product based on the requirement. 


3. Picking

Picking is the costliest process of warehousing. In this process, the goods are collected for the fulfilment of customer orders. The accuracy of this procedure is essential for complete customer satisfaction. Making sure that the right order makes it to the correct delivery location on time is vital. For this, picking the correct goods on time is critical on the warehouse’s end. 


There may be two proceedings after the pickup. One may be simply sending it off to the packing table for dispatch, while the other is where the picked goods are allotted to specific group orders or individual orders. Often, orders are picked up as soon as they are received, known as the real-time ordering system, while sometimes specific pickup times are preassigned and several orders are dispatched on those particular time in waves.


Put walls, put-to-light systems, goods-to-person systems, and cross-belt sortation systems are new technologies being implemented with the advent of online shopping. They help in the proper handling of small bulk orders. Essential technologies such as mobiles and wearables allow the workers tally their lists wirelessly and more efficiently. 

Improvement of Warehouse Order Picking Activity - Research and Models


3a. Kitting/Dekitting

The kitting process includes collecting all items of an order individually into a single box or “kit”. It is followed by packing them together instead of picking and packing each item separately. Hence, the company creates a single unit in the inventory. 

Through this process, the time taken to complete each order is reduced. The staff can avoid unnecessary efforts on processing items individually. Thus, the process of order fulfilment and inventory becomes easier. Companies gain a competitive edge due to the increased worker productivity and efficiency brought about by the kitting technique. Since this process is completed in one go, the scope for error in completing an order is reduced. The time and material wasted on packing each item separately in boxes is saved since the workers can now pack one custom box directly.

The dekitting process is an exact opposite of the kitting process. All the items that are part of a kit are de-assembled and placed separately in their designated places. 


4. Packing

Packing is the process of preparing the picked items for shipment. Workers have to pack these items and ensure that they are safe even after they leave the warehouse. Goods are placed in boxes or poly mailer, and specific packing material is added along with a label. The various batch item and manufacturing codes should be added while packing using stickers. The box must be lightweight, easy to carry and handle. 

The warehouse activities require quality assessment at each step. Choosing the appropriate kind of packing material and method is necessary based on the product’s need. Specific codes should be used to trace the goods back to the systems to prevent theft and misplacement. Accumulation of goods from different warehouse sections to complete certain orders is also carried out while packing. 

Specific softwares analyze the already existing data present in the system to determine the appropriate packaging for the particular goods. These have helped optimise the packing process.

5. Dispatching

The principal governing factor for the dispatching process is the time of delivery. Based on that, the operations manager plans the packaging and dispatch procedure. If this process is not carried out, it will lead to delayed delivery times.  However, at the same time, a balance is necessary. If goods are packed too ahead in time, it may lead to overcrowding of conveyor belts or similar structures. Whereas a late dispatch may lead to late deliveries. 

6. Shipping

Shipping is the first step for the product on the path to reach the customers. In this process, deliverymen categorize and group the orders. They are supposed to take the shortest routes for the shipment. Along with this, they have to deliver the right order to the designated customer at the proper address. Also, they ensure that the product stays intact with no damages on the way. The best way to manage this is by packaging the goods for shipment near the shipping docks.

Many times companies use outsource their shipments. They hire certain shipment companies to take the orders from the warehouse to the customers. Businesses arrange for methods to track their orders while they are on the way to their destination.

Labour management systems, shipping applications and devices are the methods that companies can use to optimise the shipping procedure. Computerised systems help improve efficiency and reduce the burden on human labour. 

8. Casing

Casing is when goods are picked up directly while stored in their cases from their respective storages. Mostly, fragile items are stored in such cases. Companies devote parts of their warehouses towards picking up these cases along with the goods. 

Traditionally, casing has been considered a job for manual labour however now it has been modernised. The use of automated conveyor belts has been prevalent for the transfer of large cases.

9. Inventory Tracking

Inventory Tracking is the process of accounting for all items stored in the inventory of the warehouse. An inventory mainly consists of the stock of goods already present in a warehouse. While tracking, one has to consider the inflow and outflow of the items based on the previous and new orders. Hence, it is like a consolidation of information regarding all goods present in a warehouse. Two important components of inventory are – time and speed of inventory inflow or outflow. 

One can take two approaches while carrying out inventory tracking – serial or lot tracking. 

Serial tracking – Used for expensive items that are sold in lesser quantities.

Lot tracking – Used for budget-friendly items sold in large quantities.

Several softwares that help in such management have been developed recently. These softwares may work on ERP systems or stand-alone systems. 

Warehouse managers play a significant role in inventory management. 

10. Value-Adding

 In this process, the warehouse company adds certain features as final touch-ups. It can be a complex process as several different products may be a part of an order and need separate touch-ups. At the same time, there are goods made of several components whose value-addition process becomes even more complicated. Through this process, they aim to increase the revenue or even decrease the cost of production. 

11. Returns

They are  to be prepared for returns by allocating space for returned items in the warehouse. If products are damaged and need to be discarded, accounting of the same is necessary. However, if goods are in shape, they may be recorded  and simply put up for reuse or resale.

 It will account for the extra expenses on return processes such as picking, repair, repacking etc. Software and technology have helped in this process as they reduce manual error as well as labour. 

12. Reporting and Analytics

An essential part of the warehouse process is the reporting or recording of all happenings in a warehouse. Starting from the arrival or receipt of the order to the shipment followed by the return procedure, all should be accounted for. There should be a proper database for all the inflows and outflows of the warehouse, along with the costs incurred. It helps in estimating how many resources and labour the company may require. All transactions and payments must be recorded and tallied. 

Next, another process is that of analytics. Proper assessment of the functioning of the warehouse is necessary. Whether the workforce is efficient and fulfilling their duties and jobs has to be checked. 

13. Damage control

Ensuring that the goods stored in the warehouse are protected from all damage is necessary. To fulfil this responsibility, warehouse staff should store all goods based on their size and weight. Specific protection racks should be provided for fragile goods. At the same time, staff training to manage all accidents should be carried out before recruitment. A clean and hygienic environment is also necessary to prevent damage to food products or perishable goods. Warehouse services should also consider the weather of their location and build infrastructure accordingly.  Lighting should be well maintained so that no errors or accidents may take place.


Stretch wraps and safety traps are also used to prevent goods from damage.


The efficiency with which the above processes are carried out is the responsibility of industrial engineers. 

https://www.to-increase.com/business-productivity/blog/improve-the-efficiency-of-warehouse-processes-why-and-how

https://www.wonolo.com/blog/how-to-improve-warehouse-operations/  Interesting 51 tips with links to twitter messages

https://stockarea.io/blogs/13-key-warehousing-process/

https://www.mmh.com/topic/tag/Warehouse_Operations

https://legacyscs.com/warehouse-and-distribution-center-11-best-practices/


Implementation of technology in warehouse operations

https://www.diva-portal.org/smash/get/diva2:1572242/FULLTEXT01.pdf

https://www.codelessplatforms.com/blog/27-automated-processes-improve-warehouse-operations/


Warehouse Processes - Warehouse Management - Books

Warehouse Management: The Definitive Guide to Improving Efficiency and Minimizing Costs in the Modern Warehouse

Gwynne Richards

Kogan Page Publishers, 3 Nov 2021 - Business & Economics - 536 pages

Modern warehouses are capitalizing on cutting-edge technologies, new operating models and innovative practices to maximize their role in the wider supply chain. Understand how to successfully manage these warehouses with this bestselling guide.


The fourth edition of Warehouse Management is fully updated to include up to date information across the board. The latest technologies in warehousing, such as robotics, cobots and AI, are explained and their impact is situated alongside discussions on the future of warehousing. There are new case studies from companies who have achieved improvements and cost savings through the introduction of new technology and equipment, leaner processes and environmental initiatives. Gwynne Richards provides expert advice with clear and easy to grasp solutions.


Warehouse Management guides the reader through all aspects of successfully managing a warehouse, its operations and distribution. This bestselling book covers an extensive range of key topics from defining the modern warehouse, detailing management processes, strategies and practices to outlining how to tackle environmental challenges to ensure a sustainable supply chain. With practical insights into how to improve operating costs, increase efficiency and reduce costs, this is a must read for optimizing warehouse performance. New and updated online resources include PowerPoint slides and a bonus chapter on outsourcing.

Preview


Warehouse Management: A Complete Guide to Improving Efficiency and Minimizing Costs in the Modern Warehouse

Gwynne Richards

Kogan Page Publishers, 03-Jun-2014 - Business & Economics - 448 pages

Gwynne Richards' highly regarded and best-selling text on warehouse management is a complete guide to best practice in warehouse operations. Warehouse Management examines how to operate an efficient and cost-effective warehouse. It provides guidance on using the latest technology, reducing inventory, people management, location and design. Covering everything from the latest technological advances to current environmental issues, Warehouse Management provides an indispensable companion to the modern warehouse. The text considers key aspects of warehouse management, including cost reduction, productivity, people management, and warehouse operations.

In addition to providing updates on future advances in warehouse management, Gwynne Richards tackles the key issues that are challenging today's managers, including pressure to reduce lead times, increase productivity, reduce cost, improve customer service, reduce environmental impact, and maintain health and safety standards.

Offering comprehensive direction on all aspects of managing a warehouse, Warehouse Management is an ideal guide and detailed reference book for anyone looking to gain a real insight into warehouse operations.

In this 2nd edition of Warehouse Management, there are more case studies, photographs as well as extensive accompanying online resources, such as PowerPoints and video links.


The Warehouse Management Handbook

Jerry D. Smith
Tompkins Press, 1998 - Business & Economics - 980 pages

Completely revised to reflect recent developments ranging from ADA requirements to re-engineering, benchmarking and cycle-time reduction, this book provides advice on planning, equipping and managing every aspect of the warehouse operation. It includes such topics as: changing technologies; specific planning data; valuable implementation guidance; and new case studies from such companies as Abbot Laboratories, Rubbermaid, Ross Stores and Sara Lee.

https://6river.com/expert-tips-on-improving-warehouse-efficiency-productivity/

https://scm.ncsu.edu/scm-articles/article/improving-your-manufacturing-operations-using-warehouse-automation

https://ie.binus.ac.id/2016/02/02/eleven-ways-to-optimize-your-warehouse/

https://www.anylogic.com/modeling-operations-at-pharmaceutical-distribution-warehouses/

https://www.ijitee.org/wp-content/uploads/papers/v9i1/A9176119119.pdf

https://www.inderscience.com/info/inarticle.php?artid=81962




















Ud. 6.10.2024
Pub. 6.10.2021

Saturday, October 5, 2024

Warehouse and Storage System - Warehouse and Storing Processes Industrial Engineering - Introduction


Industrial engineering investigates storage facilities and activities as part of process analysis for productivity and cost reduction. It also studies the facilities and activities at the system level or factory level. It utilize available facilities and activities in various processes.

Storage is an operation captured in the flow process chart and is one of the five standard operations included in the flow process chart. Storage facilities will be for work-in-process on the shop floor, raw materials, finished goods, tools, inspection gauges, jigs and fixtures etc. Storing in appropriate bins and drawers can result in quick pick up and delivery of items from the store. It can reduce the operator or helper time wasted in waiting at the store.

Boeing advertises for a job in Warehouse Industrial Engineering

FULFILLMENT METHODS PROCESS ANALYST

Renton, Washington; Everett, Washington

Job ID 00000291030
Date posted 01/20/2022

Boeing Commercial Airplanes is seeking a Mid-Level Methods Process Analyst (Level 3) to support our Fulfillment & Program/Customer Integration team in Renton and Everett, Washington.

The Fulfillment organization provides seamless support to customers, both internal and external, modernizing how to receive, track, and deliver parts. Fulfilment manages products from on dock through last stage kitting to point of use. 

Areas of responsibility include but not limited to: hazmat and consumables, standards, small and bulk parts, tooling, expedite, and material integration center support.

The ideal candidate will utilize industrial engineering concepts, manufacturing operations knowledge and business acumen.

Position Responsibilities:

Applies Industrial Engineering and/or lean concepts, techniques, analysis and decision tools to promote and implement changes in manufacturing, engineering and service operations.

Develops models, data bases and/or spreadsheets to analyze data and provides summary analysis and metrics for consultation to customers (e.g., management, departments, suppliers).

Assists in the identification and implementation of process improvements by analyzing current processes and utilizing established improvement methodologies to maximize the efficiency of equipment and personnel and to support company improvement initiatives.

Analyzes and designs value stream, including capability, capacity (e.g., make/buy, supplier selection, risk analysis, supplier performance), throughput, work flow and logistics (e.g., critical path, lead-time, transportation, factory layout).

Supports efforts to develop, implement, maintain and monitor status of shop operating plans to maximize the efficiency of equipment and personnel in order to meet schedule commitments.

Gathers and analyzes shop performance metrics in order to support a recommended plan of action.

This position is expected to be 100% onsite.  The selected candidate will be required to work onsite at one of the listed location options.

This position must meet Export Control compliance requirements, therefore a “US Person” as defined by 22 C.F.R. § 120.15 is required. “US Person” includes US Citizen, lawful permanent resident, refugee, or asylee.






The little book of warehouse solution design: Solution designing from scratch to a concept. 

by Vinayak Kamlakar Shete (Author)  -  Kindle Edition, ₹199.00

https://www.amazon.in/dp/B09QXY8N2F/ref=sr_1_1?crid=RQHSQGV3F5ER

Storage and Warehouse System - Process Improvement - Flow Process Chart Based Industrial Engineering - Module Lessons



Writing this lesson turns out to be a difficult exercise. Books on Motion and Time Study, that discuss process charts do not have content on this topic. There is need to collect more materials and develop a more clear content one that especially focuses on the flow process chart based process improvement. But to reach that goal, the available materials are to be identified, read, consolidate in a loose way first.

There is a need to distinguish between plant level facilities planning and facilities industrial engineering and process improvement industrial engineering based on studies based on process charts and related information. In process industrial engineering the focus is on process chart based industrial engineering and the basic knowledge of the processes (theoretical) involved in each of the five operations in the flow process chart.  Processing, Inspection, Transport, Warehouse and Production Planning and Scheduling (Temporary Delays). Facilities planning and industrial engineering may be included in the Process IE for the present. Or it could be added as an additional module.


Storage Space and Arrangement  Around Work Station and on Shop Floor

Maximizing Storage Space at Your Workstation

Organizing materials to coincide with the flow of the work creates efficiency.

https://www.dehnco.com/insights-resources/articles-resources/maximizing-storage-space/

Work station storage device of intelligent clothing product-o-rial system

2014

https://patents.google.com/patent/CN203714684U/en

Evaluative Models of Discrete Part Production Lines

May 2009

DOI:10.1007/978-0-387-89494-2_2

In book: Analysis and Design of Discrete Part Production Lines (pp.25-99)

https://www.researchgate.net/publication/227010771_Evaluative_Models_of_Discrete_Part_Production_Lines


Stores and Warehouses

Going (1911) on Stores

An effective stores system should accomplish at least four things :

First. It should prevent over-investment and unbalanced accumulation. Of course, an extraordinary purchase to secure advantage of special market conditions, although leading to a temporary over-investment or overbalance of some item of stores, might yet be very wise.

Second. It should give automatic warning of approach to a minimum on any item, so that the danger may be averted by filling up the low points.

Third. It should provide effective means for getting the material through the factory rapidly and without delays, even up to the final delivery of the finished stock.

Fourth. It should furnish records of every delivery, so that each order can be traced and identified with the job and with the workmen, and so that every part or piece may be accounted for and a continuous inventory of stock on hand may be obtainable.

It is apparent that these requirements connect the stores department very closely with the purchasing department on the one side, with the cost department throughout, and with the shipping department on the other side. Under able and energetic administration, indeed, it may be made (and in some modern institutions it is being made) not simply a bureau of custody and record, but a leader and a driver of
the manufacturing superintendents and the operating officers. Even though it have no executive authority over manufactures, it can and it should disclose delays, inefficiencies, irregularities, and extravagances and bring them to the attention of the executives for correction.


Going 1911



Richard L. Shell on Warehouse Industrial Engineering

Summary of CHAPTER 9.5 (Maynard Handbook 5th Edition)

PLANNING AND CONTROL OF SERVICE OPERATIONS

Richard L. Shell, University of Cincinnati, Cincinnati, Ohio

Introduction


Storage and warehousing operations are a critical part of a profitable business. There are nearly 300,000 warehouses spread across the length and breadth of the United States employing nearly 2.5 million people with the cost of warehousing being nearly 5 percent of the gross national product.

Warehouse planning must be constantly scrutinized and must be tailored to meet anticipated future requirements. The functions performed by a warehouse can be defined as follows:

● Receiving the goods from a source

● Storing and keeping track of the goods

● Picking the goods when they are required

● Shipping the goods to the appropriate customer

Requirement and Strategies for Successful Warehousing

A successful warehouse operation typically adheres to the following thinking. 

● Warehousing is a critical step in the material flow. 

● Warehouse operations must be aware of the customer’s requirements and consistently meet those requirements.

● Warehouse standards must be established, performance must be measured against standards, and timely actions must be taken to overcome any deviations.

● Systems must be put in place and must be conducive for proactive decisions.

● The trend is toward larger, centralized warehouses instead of smaller, decentralized warehouses.

● Warehouses need to be flexible—allowing for multiple uses.

● Activities within the warehouse must be more integrated into the overall material flow cycle.

● Cycle counting must be used to manage inventory accuracy, and accuracy above 95 percent must be the norm.

● Procedures and layouts must be designed to maximize picking efficiency and effectiveness in terms of correct ergonomic design and safety considerations.

● Vendors, customers, and a wide variety of functions within the warehouse must be integrated into a single service-providing activity.

● Advanced technologies must be more easily embraced and economically justified.

● All warehouse operations should be conducted to ensure conformance to customer requirements.

● Automatic identification systems must be the norm for data acquisition and transfer.

● Real-time, paperless control systems must be used throughout modern warehouses.

Warehouse Objectives

The resources of a warehouse are space, equipment, and personnel. The cost of space not only includes the cost of building or leasing space but also the cost of maintaining and operating the space. The equipment resources of a warehouse include computers, dock equipment, loading and material-handling equipment, and storage equipment, all of which combine to represent a sizable capital investment in the warehouse. The following objectives must be met for a warehouse to be successful:

● Maximize effective use of space.

● Maximize effective use of equipment.

● Maximize effective use of labor.

● Maximize accessibility of all items.

● Maximize protection of all items and employees.


RESOURCE PLANNING TO SATISFY DEMAND

Resource planning is the process of determining the types and amounts of resources that are required to implement an organization’s plan. The goal of resource planning in  warehousing and distribution is to determine the appropriate level of service capacity—as represented by facilities/space, equipment, and labor—that is required to meet future service demand.

Capacity Planning

Capacity planning strategies at a typical warehouse involve an assessment of existing capacity, forecasts of future capacity requirements, a choice of alternative ways to build capacity, and a financial evaluation. In developing a long-range capacity plan, a firm must make a basic economic trade-off between the cost of capacity and the opportunity cost of not having adequate capacity. Capacity cost includes both the initial investment in facilities and the annual cost of operating and maintaining the facilities.

Output measures of capacity for service production are more difficult to interpret and control, since the rate at which humans work is more variable than that of machines. Therefore, input measures are more commonly used. Service organizations should forecast the human effort involved in providing necessary services.

Storage Space Planning

Space planning is the part of the science of warehousing concerned with making quantitative assessment of warehouse space requirements. Space planning consists of the following general steps:

1. Determine what materials are to be stored.

2. Determine the storage philosophy.

3. Determine space allowances for each element required to accomplish the activity.

4. Calculate the total space requirements.

The first two steps of the space planning process define the activity, techniques, equipment, information, and so on to be used in performing that activity. Once the maximum inventory levels have been determined, the inventory level that will be used as a basis for planning required storage space must be calculated. There are two major material storage philosophies: 

fixed (or assigned) location storage and random (or floating) location storage. In fixed location storage, each individual stock-keeping unit will always be stored in a specific storage location. No other stock-keeping unit may be assigned to that location even though the location may be empty. 

With random location storage any stock-keeping unit may be assigned to any available storage location. The amount of space planned depends on the method of assigning space. If fixed location storage is used, then sufficient space must be assigned to store the maximum amount of stock-keeping units that will ever need to be stored at any time. For a random location storage unit, the maximum amount of items on hand at any time will be the average amount of each stock-keeping unit. Usually the storage philosophy for a specific stock-keeping unit will not be strictly fixed, and during most of the time, the storage philosophy might be a hybrid of the two.

Each of the discussed storage philosophies has its own merits and limitations. Space utilization is poor in a fixed location system, while it is far better in a random storage system.

However, accessibility of material stored in a fixed storage system is better because the location of a particular product is always known. Accessibility to material in random storage systems depends on a good material locator system. The material locator system keeps track of the present location of every item in storage. In both fixed and random storage location systems, the flow of material is straightforward and economical. The third step involves determining the space requirements of each element that contributes to performing the activity. In warehousing, these elements commonly include personnel services, material handling and material storage requirements, and maintenance services and utilities. Finally, step four combines the space requirements of the individual elements to obtain total space requirements.

Storage space planning is particularly critical because the storage activity accounts for the bulk of the space requirements of a warehouse. Inadequate storage space planning can easily result in a warehouse that is significantly larger or smaller than required. Too little storage space can result in a horde of operational problems like lost stock, inaccessible material, safety problems, and low productivity. Too much storage space will result in poor use of resources and high space costs in the form of land, equipment, and capital.

Labor and Equipment Planning

For a firm that employs a large number of service providers, labor or staffing levels and equipment can be the primary capacity constraint. A warehouse and distribution operation, being very labor and equipment intensive, may face the reality that at certain times demand for their organization’s services cannot be met because the staff or equipment is already operating at peak capacity. However, it does not always make sense to hire additional service providers if low demand is a reality at other times. In this situation, the firm should attempt to hire part-time workers during high demand times.


Work Measurement Techniques for Warehousing Operations

Good management means knowing what can be expected from employees, and that requires establishing performance standards. Such standards are needed to determine

● Labor content of the service performed

● Staffing needs of the organization

● Cost and time estimates prior to performing services

● Productivity expectations

● Wage incentive plans

● Efficiency of employees

Properly set standards represent the amount of time it should take an average employee to perform the specific job activities under normal working conditions. Similar to the manufacturing sector, labor standards in the service sector are established by using traditional work measurement techniques. 

There are customized work measurement techniques such as specialized predetermined time systems for specific applications. For example, AutoMOST has been used to automatically determine performance standards from a specific set of variables for the order-filling functions in warehousing operations.

The advantages of a work measurement program include

the following:

● Capital equipment investment justification

● Compensation and incentive payment

● Credible service cost

● Effective organization size and structure

● Labor requirements and unit labor cost

● Planning, control, and budgeting

● Service pricing

● Quality attainment and monitoring

● Scheduling of both labor and material movement

● Work design and human factors considerations

(To be rewritten further)


BIOGRAPHY

Richard L. Shell, Ph.D., P.E., is professor of industrial engineering in the College of Engineering and is professor of environmental health in the College of Medicine at the University of Cincinnati. His specialization areas include ergonomics/safety engineering, human performance, incentive motivation, and manufacturing. He received the Institute of Industrial Engineers Fellow Award in 1988, and was elected a fellow of the Society of Manufacturing Engineers in 1995.

His most recent book, Time Based Manufacturing, was coauthored with Joe Bockerstette and copublished by Industrial Engineering and Management Press and McGraw-Hill.


Herbert W. Davis - WAREHOUSE MANAGEMENT

Summary of  CHAPTER 10.3 (Maynard's Handbook,5th edition)

WAREHOUSE MANAGEMENT

Herbert W. Davis, Herbert W. Davis and Company, Fort Lee, New Jersey

The modern distribution center is very different from the storage warehouse of pre-1960 multilevel industrial practice. Today’s facility is large, high, and complex. A typical warehouse of the late 1990s may be 200,000 to 500,000 square feet in floor area, have stacking heights of 25 to 35 feet, have tens of millions of dollars of installed equipment, employ hundreds of people, and ship a daily throughput rate of several thousand tons of material.

These complex facilities are the direct result of the application of industrial engineering concepts and practice to the multicompany, multifacility supply chains that move finished products from source to customer. This chapter describes the functions of the warehouse and the use of industrial engineering techniques in the design and operation of the facility. 


WAREHOUSING LEVELS

The storage and handling of materials is an important function in manufacturing and distribution. Storage levels normally used in the industrial process are as follows:

● Raw material stores (chemicals, bar stock, component parts)

● Tool cribs (molds, dies, cutting tools)

● Maintenance supplies (paper, oils, electrical, and plumbing repair parts)

● In-process materials (items stored between manufacturing operations)

● Plant finished-goods warehouses

● Public distribution centers

● Private distribution centers

● Bonded warehouses (usually for imported goods held while awaiting the payment of customs charges or for transfer to another country; may be for products on which local or federal taxes have not yet been paid)

In the general case, storage and warehousing occur in or near either the plant or the market.  Plant-located facilities either serve the plant operations (raw materials and tool cribs, for example) or are a major customer shipping point. The plant warehouse may also be the backup point to resupply a field distribution system. 

The public warehouse  might contract to do price ticketing, assembly and repacking, labeling, inbound material consolidation, outbound customer freight consolidation, and order receipt and entry. Public facilities with a tie-in to transportation carriers can also offer product tracking and status reporting. These services, added to an already high level of warehouse productivity, have resulted in public warehousing growth rates higher than that of company-operated facilities.

WAREHOUSE DESIGN

The methods used to design the materials flow, handling, and storage activities and to control labor productivity in a modern distribution center are similar to industrial engineering practice in a manufacturing plant. There are a number of special conditions, however, in distribution facility design and operations that could be helpful to the industrial engineer in designing the facility.

Building Considerations

Many warehousing facilities are located inside manufacturing plants. In such cases, it is common to find that the building is constructed to meet manufacturing needs (stacking heights, floor storage arrangements, bay sizes, etc.). This practice results from the common use of space by both activities. Manufacturing frequently expands into the space occupied by warehousing.

In freestanding distribution centers and on a few plant sites, the warehousing facility is designed to fit the unique characteristics of the distribution system. For example, modern stacking equipment can economically operate at heights of 40 to 85 feet or more. Some equipment can right-angle stack in a 5-foot-wide aisle. Other equipment may be secured to the building structure or the storage racks. The need for such dense storage patterns results in the design and construction of special-purpose buildings that are not generally useful for manufacturing. In designing the modern distribution center, the industrial engineer must consider the following factors.

Material Flow. The building can have a straight-through flow with receiving on one end and shipping on the other. Another popular approach is a U-shaped flow with common receiving and shipping areas. This method concentrates most of the building employees and activities for better control. Both methods are effective; the best choice can be determined based on economic analysis and site configuration.

Levels. Older facilities—and some very modern distribution centers—are frequently multilevel. Storage, however, is most efficient when concentrated on one floor level with a high stack height. Receiving, shipping, and packing operations, on the other hand, seldom require high ceilings. Normally, horizontal travel is less costly than vertical, leading to the current interest in single-level warehouses. The industrial engineer must reconcile these factors in preparing the design.

Bay Dimensions. The storage pattern is a crucial factor in distribution center design. The buildup of storage spots and access aisles dictate the bay dimensions. Proper design can result in efficient or optimum bay dimensions. A bay is the floor area bounded by the building support columns. Forty years ago, it was not uncommon to work with 3-foot-diameter concrete columns on 20-foot centers. In this situation, storage patterns were relatively inefficient. Current construction allows about 8 to 12 inches for steel columns, spaced 30 to 60 feet on centers.

Note that the storage pattern is determined first. Then the column spacing is calculated to locate columns within the rack or storage structure. The final spacing may be any multiple that minimizes column space loss while providing a lower-cost, steel-frame roof structure. The final dimensions are decided by building cost calculations designed to balance the cost of lost space with that of extra-long steel members.

Ceiling Heights. The vertical distance between floor and lowest structural obstruction in a modern distribution center is determined by the storage stack height and the clearance needed for water dispersion from sprinkler heads. The storage area may contain storage racks on which palletloads of material are placed. There may be bulk stacks where palletloads are continuously stacked to the crushing limit. Pallet racks, however, normally are used in buildings with very high stack heights, because current lift equipment is capable of safely stacking much higher loads than product crushing limits or stability would permit. 

Mezzanines. Because most modern distribution centers are constructed on a single level, the use of temporary and/or permanent mezzanines is an important building option. Mezzanines may be constructed with steel grating supported by storage racks, special columns, or building columns. They are used to more fully utilize the cubic space in a building. Typically, a warehouse may have storage covering 50 to 75 percent of the floor area. The other operations such as receiving, counting, marking, packing, and staging may total 50,000 square feet or more, but may not effectively utilize the warehouse height of 30 or more feet. Thus, two or three overhead levels might be constructed to house these activities more efficiently.

Number of Truck Doors. Doors are expensive, in both construction costs and energy loss. Determining the right number of truck and utility doors is complex, frequently requiring the use of simulation. Doors may be single-purpose (receiving, shipping, over-the-road trailer, etc.) or multipurpose to fill all needs. Most warehouses are built with the floor 48 inches above grade and pavement. This provides for forklift access to typical highway trailers. Special-purpose docks for vans (24 inches) and ground-level access for inside loading may be provided.

A method to accurately estimate the number of doors needed requires accumulating a record of truck arrivals (or unloading) and a separate record of outbound loads. The industrial engineer needs to measure the average loading or unloading time for a sample time period. Given the average arrival and departure frequency and the average load/unload service time, queuing theory can be employed to determine the appropriate number of docks. Queuing tables are available to simplify calculation.

Length-to-Width Ratios. In many cases the available land dictates the general configuration of the warehouse building. Given unlimited sites, however, the ratio of building length to width is a useful design element. The selection depends on the desired materials flow and the handling/storage method used.

U-Shaped Flow. The docks may be on one common wall to maximize control and cross-utilization of personnel. Buildings tend to be constructed square or to a 3:2 length-width ratio in these circumstances to minimize internal movement. Expansion is usually on the back wall opposite the truck dock wall. This provides for low-cost additions since the expansion need only provide lighting and minimal support services. Everything else is in the original building section. It is also easy to expand on the other two walls if appropriate.

U-shaped flow has become the most popular building shape over the past 20 years. The reason is that it permits storing the most active products close to both the receiving and shipping docks. Thus, the industrial engineer can minimize travel distance on the items with the largest pallet movements. Also, it tends to group most employees in a small area, simplifying supervision. Overall staffing for the facility is thus minimized.

Increased use of computerized warehouse management systems has improved location and labor control, making U-shaped product paths easy to maintain.

Rectangular. Straight-through materials flow buildings have docks at opposite ends with storage rack aisles parallel to the flow so that an item can move in a straight line from receipt to storage, picking, and shipping. The building width is a function of the number of truck doors needed, which will be on about 12-foot centers. Thus, if 10 doors are needed for shipping, the building may be 120 to 150 feet wide. The long dimension is calculated to provide sufficient area for staging, storage, and operations. Typical ratios are from 1:2 up to 1:5. Expansion of straight-through-flow buildings is on the long side to provide for additions to all the operations roughly in proportion to the original space allocations. Straight-flow buildings have an inherent operating disadvantage: all material must traverse the entire long dimension.

Hybrid. Some warehouses have a large number of quite different activities dictated by product or corporate circumstances. Examples are cool and frozen material storage rooms, unit repacking or packaging functions, hazardous materials items, and so forth. These special circumstances result in buildings that do not meet the general types described. A common hybrid today occurs when the building storage area is designed for very high storage. Stacker cranes can store products 85 or more feet in height and typically require only very narrow aisles 5 feet or less in width. In these cases, unique building specifications may be used to control access and environmental conditions in the storage module.

Warehouse Equipment

Most warehouses use conventional-style equipment for the storage and movement activities.

Some conventional items are as follows.

Pallet Racks. These are used to store pallet-loads of product at multiple levels, making better use of floor space.  Conceptually, racks are storage structures constructed of formed steel with uprights fitted with movable bars set at appropriate heights to accommodate pallet-loads. Racks are usually strung in long lines with access aisles between them. A typical arrangement has a module consisting of a row of racks holding 4-foot-deep pallets, an 8- to 12-foot access aisle, and another row of racks. Other types of pallet racks are for double-deep drive-through or storage to store pallets deeper. Finally, racks may be fitted with steel or plywood shelves to accommodate individual cases and small parts.

Storage Bins. Usually of steel, bins are short sections of shelving designed to hold small lots of material. Many configurations are used, including drawers, slotted dividers, differing shelf heights, and reinforcing bars for heavy materials.

Flow Racks. Picking of individual items and small cases from bins or pallet racks may become laborious. For some high-volume operations, flow racks are used. A flow rack is usually a rack 8 to 10 feet wide and as deep or deeper. Slide- or roller-equipped angle frames permit loading a case at the rear of the rack so that it will flow down the lane to the picking face. A few to a dozen cases may be contained in a flow lane. Each rack may be six or eight lanes wide and three to five high—a total capacity of perhaps 20 to 30 different items, each supported by a continuous feed of 10 cases or more. This gives a dense, usable storage pattern to support high-volume order-picking activities. In this arrangement, the picking face presents many more items to the picker per foot of access aisle compared to conventional bin or pallet rack storage. The industrial engineer, however, should observe that flow racks typically require that every case be handled twice: in and out. Thus, the highest-volume items are most often stored in pallet-loads, not in case flow racks. The best use of case flow racks is for medium-usage items. A related common technique is to use pallet flow racks for items that are very high volume.


(To be rewritten further)

CHAPTER 10.6
CASE STUDY: LESSONS LEARNED FROM IMPLEMENTING A PAPERLESS WAREHOUSE
MANAGEMENT SYSTEM
Steve Mulaik
The Progress Group
Smyrna, Georgia
Bob Ouellette
The Progress Group
Roswell, Georgia


Storage Racking Systems




Eleven Ways to Optimize Your Warehouse

02 Feb 2016 - Binus University IE Department Article

Based on statistics, warehouse labor is consumed in the following manner:

Order picking, 54 percent
Truck loading, 4 percent
Packing/packaging, 4 percent
Other, 14 percent

Warehouse Productivity - Articles

The Warehouse Productivity Guide: How To Improve Warehouse Productivity & Efficiency
About LPC International Ltd,  Logistics Planning Consultants.

Top 3 Ways Autonomous Mobile Robots (AMRs) Increase Warehouse Productivity and Efficiency

Logistics Software Implementation in Warehouses - One of the three warehouses showed stabilization of workforce productivity at a level 50% higher than before the implementation.
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How to Improve Order Picking Productivity in Your Warehouse
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Four Ways to Boost Warehouse Productivity That Aren't Automation
March 31, 2022, Steve Shaheen.

Allen Distribution improves warehouse productivity with Prime MobileShelf
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Warehouse Productivity: 15 Experts Reveal Their Top Tips for More Efficient and Productive Warehouse Operations
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Automation has reached its tipping point for omnichannel warehouses
December 27, 2021

50 expert tips on improving warehouse efficiency & productivity
CHRIS DUNAKIN.  DECEMBER 21ST, 2021



HOW TO MEASURE WAREHOUSE EFFICIENCY
October 26, 2021, Hamed Ali

Systems Engineering Practices to Increase Warehouse Efficiency and Productivity
NORM NOPPER, 15TH OCTOBER 2021

Metrics for Warehouse Productivity
Kevin Suh, Aug 12, 2021 

How To Improve The Warehouse Receiving Process
Newcastle Systems,  Wed, Jun 09, 2021

A Retailer Increases Warehouse Picking Productivity By 50% With Automation
Steve Banker, 19 May 2021.

How Autonomous Cleaning Solutions Boost Warehouse and Supply Chain Productivity
Leading facilities are now turning to autonomous cleaning solutions to unlock new operating efficiencies while reducing cost and improving warehouse safety.
May 17, 2021









Ud. 5.10.2024, 13.6.2022,  16.5.2022,  22.1.2022
Pub  6.10.2021