Racking%20In%20The%20Foodservice%20Warehouse

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Racking In The Foodservice Warehouse
W. Frank Dell CMC President DELLMART
Company 125 Hardesty Road Stamford, CT 06903
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Agenda

• INTRODUCTION
• RACKING OPTIONS
• MECHANIZATION OPTIONS
• EQUIPMENT OPTIONS
• DESIGN ISSUES
• SUMMARY

DELLMART COMPANY
MANAGEMENT CONSULTANTS
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Objectives

• Explore different types of racking or storage
  mediums
• Understand the advantages and disadvantages of
  each type
• Review the supporting equipment

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Warehouse Design Rational Include

• Store Capacity
• Selection Slots
• Labor Productivity
• Through-Put

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Terminology For Warehouse Processes

• Inbound
• Receiving
• Put-Away
• Outbound
• Replenishment
• Selection
• Loading

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Procurements Impact On Warehouse Requirements

• Storage Capacity
• Selection Slots
• Receiving Doors Dock Space
• Storage Type

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Pallet Size Should Be Determined Jointly By
Buying And Warehousing

• Cycle Stock Pallet Quantity
• Pallet Quantity
• Ordering Concepts
• Fixed Review
• Just In Time

2 X Put Away Cost Holding Cost
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Customers Impact On Warehouse Requirements

• Sales Volume
• Order Size
• Pick Density
• Number of Orders
• Shipping Doors and Dock Space

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Direct Labor Fundamentals

• Every task has a fixed time component
• Travel Standards
• Walk
• Ride
• LIft
• Case Handling Standards
• Case
• Cube
• Weight

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Agenda

• INTRODUCTION
• RACKING OPTIONS
• MECHANIZATION OPTIONS
• EQUIPMENT OPTIONS
• DESIGN ISSUES
• SUMMARY

DELLMART COMPANY
MANAGEMENT CONSULTANTS
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Floor Stack

• Usage - Selection, reserve and bulk storage
• Application
• Large case cube
• High velocity
• Low roof

Advantages
Disadvantages
Floor space utilization 2 Replenishment per 3
selection pallets Flexible deep Minimal capital
cost
Height restriction (Max. 3 pallets high) Product
rotation Product damage
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Single Deep One High Select

• Usage - Selection floor slot with reserve
  overhead
• Application
• Large case cube
• Fast seller

Advantages
Disadvantages
Simple to manage Good height utilization
Reduce slot cube utilization
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Single Deep Two High Select

• Usage - Selection floor slots with reserve
  overhead
• Application
• Medium cube and velocity
• Small cube and high velocity

Advantages
Disadvantages
Increase selection slots Increase selection
density Reduce walk time
Reduce cube utilization
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Single Deep Three High Select

• Usage - Selection floor slots with reserve
  overhead
• Application
• Small cube
• Slow velocity

Advantages
Disadvantages
Increase selection slots Increase selection
density Reduce walk time
Reduce cube utilization Reduce selection
capacity Slower replenishment
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Single Deep Hand Stack

• Usage - Selection floor slot with no reserve
  storage
• Application
• Small cube
• Very slow velocity
• Broken case items

Advantages
Disadvantages
Increase selection slots Increase selection
density Reduce walk time
Reduce cube utilization Reduce selection
capacity Slower put-away Increase rotation
problems Increase selection errors
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Case Flow Rack

• Usage - Selection with reserve in lane and bulk
  storage overhead
• Application
• Case cube less than 1
• Case velocity less than 11

Advantages
Disadvantages
High selection density Keeps family groups
together
Must be linked to buying
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Double Deep One High Select

• Usage - Selection floor slot with reserve
  overhead and behind
• Application
• Large case cube
• Fast seller

Advantages
Disadvantages
Good storage capacity
Difficult to replenish and put-away Increase
rotation problems
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Drive in Rack

• Usage - Selection floor slots with reserve
  overhead
• Application
• Large case cube
• High Velocity
• Buying restriction

Advantages
Disadvantages
Multiple selection slots Maximum selection
capacity
Increase rotation problems Creates honey combing
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Agenda

• INTRODUCTION
• RACKING OPTIONS
• MECHANIZATION OPTIONS
• EQUIPMENT OPTIONS
• DESIGN ISSUES
• SUMMARY

DELLMART COMPANY
MANAGEMENT CONSULTANTS
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Pick To Belt

• Application
• Medium size cases
• Fast and medium velocity

Advantages
Disadvantages
High selection rate Controlled walk Batch select
Requires sorting step Must walk entire
system Non-conveyable cases
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Carousel

• Application
• Smaller cases
• Slow velocity

Advantages
Disadvantages
Random selection Reduce travel
Lose overhead storage Limitation on case
size Slow replenishment
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Cartrac

• Application
• Medium and large cases
• High velocity with multi-carts

Advantages
Disadvantages
Reduce travel Batch selection
Lose overhead storage Difficult to replenish
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Program Item Retrieval (PIR)

• Application
• Small and medium cases
• Slow velocity

Advantages
Disadvantages
Increase selection slots Random slots Batch
select
Require sorting step Machine paces
travel Slower put-away
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Agenda

• INTRODUCTION
• RACKING OPTIONS
• MECHANIZATION OPTIONS
• EQUIPMENT OPTIONS
• DESIGN ISSUES
• SUMMARY

DELLMART COMPANY
MANAGEMENT CONSULTANTS
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Fork Lifts

• Counter balance - wide aisle
• Straddle - narrow aisle
• Stand-up versus ride

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Fork Lift Attachments

• Pallet forks
• Slip sheet or push-pull
• Clamp
• Reach

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Single Pallet Jack

• Dock Jockey
• Put-away into floor slot
• Put-away transport
• Selection

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Double Pallet Jack (Long John)

• Put-away transport
• Selection
• Single orders
• Batch orders

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Tugger

• Carts or trucks
• Radio control

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Agenda

• INTRODUCTION
• RACKING OPTIONS
• MECHANIZATION OPTIONS
• EQUIPMENT OPTIONS
• DESIGN ISSUES
• SUMMARY

DELLMART COMPANY
MANAGEMENT CONSULTANTS
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Narrow Versus Wide Aisle

• Less floor square feet
• Greater cube utilization
• Facilitates 2 side selection
• Increases congestion and interference
• Increases damage

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Slot Column

• Spacing
• Maneuvering room
• Product
• Pallet
• Bar
• Bury columns
• Number of slot types

Rack Bar
Product
Pallet
Rack Bar
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Cross Bars

• Pair weight
• Adjustability

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Height Versus Floor

• Land cost
• 24 foot rule

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Slotting

• Family grouping
• Velocity
• Customer orders
• Density

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Layout Check List

• Dock space
• Employee area and facilities
• Battery charging area
• Repair and maintenance area
• Damage and return processing

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Agenda

• INTRODUCTION
• RACKING OPTIONS
• MECHANIZATION OPTIONS
• EQUIPMENT OPTIONS
• DESIGN ISSUES
• SUMMARY

DELLMART COMPANY
MANAGEMENT CONSULTANTS
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Summary

• Plan 5 years into the future
• Rank design rationale
• Test alternatives with labor models
• Perform quarterly maintenance

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Thank for Providing Slides
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