Effective Design and Management of Storage Facilities

2. The design of storage and handling facilities Chapter 11

3. This chapter covers the following topics: Introduction Initial requirements Sizing the warehouse Operation and warehouse management systems (WMS) Design process Fire Security Lighting Overview

4. Need to understand the principles of the layout of a facility Allows change that is efficient Introduces the principles of change or mere expansion Ongoing changes to a facility requiring adaptation and improvement The design for a new facility is specialised and beyond this text Introduction

5. Should be written and reviewed before any change Purpose needs to be explicitly defined: - Cross dock - Manufacturing storage warehouse - Distribution centre (and so on) Growth forecast Sets the size of any change to cater for the future Purpose of a facility is defined by a PPC Design requirements

6. Define the methods supported by the warehouse management system (WMS) and what is most efficient for the operation. Chart the processes. Identify limitations. Find solutions that are permitted and suit the operation. Operations and WMS

7. Identify PPCs in the products and processes For each PPC, record: - Storage requirements - Handling and moving areas - Assembly areas for transport loading and unloading Receiving requirements Design process

8. Define for each PPC: - Which areas are unique to the PPC - Which areas can be combined and the impact on space or congestion Periods of operation PPC combination and optimisation

9. If common areas are used in same period, then require increased space above single use, but less than proportion to number of PPCs that will use space. Example: a travel aisle for two PPCs need only be 50% wider than that required for one PPC use. Common areas

10. Aisle sizes between/around racks • Aisle size is determined by equipment used and traffic . • Rack volume to total floor space is important to know, as directly influences quantity of product to be stored – must be able to calculate this.

11. Methods – receiving • Interaction between receipt and put-away determines size of receiving area. • Disciplined placing in lines at all times makes for smaller size. • Partial receipt before put-away begins reduces size necessitated by receiving area.

12. Layout of receiving bay

13. Movement zones • Defined to cater for all movement that will occur, reflecting: • Number of PPCs that will use it concurrently (defined by periods of use) • Speed of equipment • Turning and stopping • Flows – one- or two-way increase the size of movement area

14. Other requirements • Pick method • Loading/unloading doors • External truck area

15. Combining areas • Requirements for each PPC • Can use CAD or drawing method • Drawing method: • - Record areas on paper layouts (cut out) • - Move around on drawing of facility • - Unique areas must be allocated so temperatures are graded from lowest to highest and flows are sensibly minimised • Common areas must be combined

16. Other issues • Fire • Safety • Security • Lighting