Warehouse design and layouts with case study and examples
- 1. Warehouse design and layouts with case study and examples Tejas V
- 2. Warehouse Design and layout • Warehouse- Place where goods are stored to balance supply and demand • Design- Process of distribution of both the external and internal space of the facility drawn on a plan • Layout- Physical design of the interior and exterior of the warehouse
- 4. Designing layout 1.Ensuring Maximum utilization of space 2. Maintaining a balance between Service and Operating Cost 3. Using the most suitable unit load 4. Minimizing movement 5. Planning and controlling movement and location 6. Providing Safe, Secure and Environmentally sound conditions
- 5. Type of material flows
- 6. Case Study Background of the company • South Italy sports equipment's and sportswear • Over 100+ Products • Two warehouses Primary and secondary Problems faced • Low pick rate with high storage • Delivery time per order was high • Multiple orders led to congestion in warehouse
- 7. Solution • ABC analysis • Cross analysis of Pareto chart • Change in warehouse layout • Increase storage capacity in primary warehouse • Changed Shelving and slotting order
- 8. Thank You
Editor's Notes
- #3: building for storing goods Stored goods can include any raw materials, packing materials, spare parts, components, or finished goods associated with agriculture, manufacturing, and production. With this Warehouse design and layout space is used efficiently and effectively and reduce travelling and time maximize warehouse function and space usage Design and layout shud satisfy these 4 primary process Product storage Inbound Outbound Value added process
- #4: EX- Amazon origin,main warehouse Amazon on the route when the product is been delivered to the customer PVT company Small Groffers, Bigbasket
- #5: Designed based on Material handeling equipment Conveyers Number of docks type of docks and location of docks
- #6: U shaped design - Excellent utilization of dock resources because the receiving and shipping processes can share dock door so Facilitating cross-docking because the receiving and shipping docks are adjacent to one anothero Excellent lift truck utilization, because the storage locations are closest to the receiving and shipping docks, they become natural locations to house fast moving itemso Yields excellent security because there is a single side of the building used for entry and exit I shape design- When there is a risk of interference or confusion between Goods In and Goods Out When goods inwards vehicles and dispatch vehicles are very different; for example differences in platform height or nature of unit loado When the warehouse is connected to a production Plant T L-shaped warehouse design sets up the traffic flow in the shape of an “L.” Loading and reception areas are positioned on one side of the building, and the shipping and picking areas are posted on the adjacent side. The rest of the space is filled with products, with plenty of space for storage.
- #7: products was stored on primary warehouse based on current demand and not forecasting when primary filled then all items would go to seacondary warehouse primary warehouse had low space than secondary Inadequate strategies for products Allocation, Products stored in Stacks, there was Lack of shelving in the central area in the second Warehouse, Lack of reception area, surface utilization was high and volume utilization was low warehouse 2 was running out of space with slow and non moving inventory
- #8: ABC analysis for categorizing the products based on their value A= High value , B=Lower than A, C= lowest Handling and transport costs are considered in the analysis and increased the primary storage space After this handling cost reduced by 7% and