Warehousing

1
Warehousing

• Yes, it is a real science

2
Outline

• Types
• Shared versus dedicated
• Operations
• Equipments
• Layout, order picking and zoning
• Pick waves
• Efficiencies
• IT

3
Storage

• Types
• Factory interfaces production with wholesalers
• Small number of large orders daily
• Retail Distribution warehouse
• Carton and item picking
• Catalog warehouse
• Large number of orders with many lines
• Support manufacturing warehouse
• RM and WIP

4
Storage

• Disadvantages of shared locations
• Workers learning
• More time to stack more locations in different
  corners of the warehouse
• Discrepancy between ERP and physical pickers
  picking from different locations than those
  indicated

5
Storage

• Advantages of shared locations
• Think of location.time
• If a product is stored as dedicated or shared
  using two pallets for two time periods

6
Warehouse operations

• Basic operations
• Inbound
• Receiving cost 10, ownership, cash flow,
  RECORD
• Put away cost 15 , locations inventory
  management, REOCRD

7
Storage and handling equipment

• Storage
• Racks for pallets
• Selective
• Cantilever
• Flow
• Drive in or through

8
Storage and handling equipment

• Storage
• Shelving for bins

9
Storage and handling equipment

• Sorting and picking
• Carousels

10
Layout/Matching
Fishbone claimed to be 20 more efficient
11
Order picking/Paths
Branch and Pick without Detouring
Branch and Pick with Detouring
12
Order picking/Addresses

• Develop a standardized addressing scheme
• Can be used with shared easily given that a good
  WMS is maintained

13
Order picking/Parallelization and zoning

• For large warehouses dividing an order over more
  than one picker is common given that an order
  consolidation process is present and a zoning
  scheme is implemented in the warehouse

14
Statistical Analysis

• Things to look at
• Order vs. order line SKUs / order, think zoning
  if high SKU /order

Order line
1
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3
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5
15
Statistical Analysis

• Data mining clustering
• Use for slotting the warehouse or creating zones
• Data mining association (develop PTSP)
• Use for path design

16
Warehousing and IT

• Advanced features
• Quality assurance modules
• RF-directed operations
• Cycle counting
• Manifesting for carton and trucks
• Returns management
• Wave management

17
Warehousing and IT

• More advanced features
• Multi-DC view
• SKU slotting
• Broken case flow
• EDI capability
• Import/Export management
• ASP capability