MODULE 7-11 Flashcards by ELIZABETH GARCIA

activity of transferring goods from reserve stock (or sometimes directly from goods-in) to the picking face

Replenishment

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often triggered when the pick face only has a certain quantity of goods left.

Replenishment

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These are common in both dedicated and shared-user or public warehouses where third-party logistics companies are providing an allen compassing service to their customers

Value-adding services

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described as a delay in the completion of an item until an actual order is received from a customer

Postponement

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necessitates the closure of the warehouse for a period of time when all inbound and outbound movements are suspended

full stock count

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involves the handling of product returns, transit packaging and surplus items.

Returns processing or reverse logistics

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The order cycle time or lead time from order receipt to despatch is continually shortening

Despatch

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manage the inventory at stock location and quantity level

stock control systems

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the software licence needed to run the system. Typically this is charged by user, PC user or radio data terminal user

license

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the costs for project management, training and go-live support.

Professional services

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software development costs for requirements not catered for in the package, including interfaces to third-party systems

Development costs

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typically an annual cost based on licence costs and often development costs;

Support cost

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The system needs to integrate with back-office tasks such as order entry, inventory control, purchase-order modules and invoicing.

Ability to interface with other systems

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look for a system where you only pay for the functionalities you require and training and implementation can be quicker

Modular and scalable

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With the mobility of staff these days it is essential that the system is accessible remotely over the web and that it is secure with access levels being password protected.

Accessible

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Select a WMS that is user friendly. Choose a system that has a point-and-click operating environment and clear, easy-to-read screens.

Ease of operation

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Ensure the system supports the widely accepted standards currently in use and isn’t limited to a proprietary standard that your customers may not use.

Standard system

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If you are involved in storing Customs and Excise goods, ensure that the system is approved or can be approved by the relevant authorities.

Meets specific needs

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Ensure the system provides comprehensive reporting suites and also reports failures.

Reporting capabilities

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Look for providers that employ staff with significant operational experience as well as staff with the ability to produce best-in-class WMSs.

Experience

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Check how long the company has been in business and what their creditworthiness is like;

Longevity

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Make sure that the WMS provider can fully support you during the implementation phase.

Resources

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internet-based application that is developed, hosted and maintained by a third-party software provider on secure servers.

Software as a service (SaaS) WMS

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your WMS vendor hosts the software application and hardware infrastructure for you

cloud computing

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These calculations are based on experience and are not intended to provide definitive answers to space requirements.

Space calculations

This area is sometimes overlooked in favour of storage space; however, this is one of the most important areas in the warehouse.

Receipt and despatch areas

what is the rule of thumb formula?

Space = (number of loads × hours to unload) ------------------------------------------------------- Time of shift × (number of pallets × space per pallet)

used to calculate the likely space requirement for staging vehicles on arrival and departure

rule-of-thumb formula

calculate the number of pallets that can be stored within a given cubic area when using standard adjustable pallet racking. (FORMULA)

(Number of width modules × pallets in a module width) × (number of length modules × pallets in module length) × number of height modules

= width of aisle + 2 pallet lengths (short side) + clearance between back-to-back pallets

module width

= width of upright + 3 × clearance + 2 pallets (long side)

module length

= height of pallet + clearance above pallet plus racking beam height

module height

It is agreed that once storage utilization exceeds 85 per cent, productivity and safety decline.

Planned utilization within the warehouse

Storage equipment manufacturers will take this into account when producing plans.

The presence and location of roof columns

The overhead pipes and sprinklers will limit the height both within the warehouse and within the racking itself

The presence and location of sprinklers (ceiling or in rack).

Different types of forklift truck will have different lift-height capabilities.

Lift height of forklift truck.

How a pallet is stored within the racking has its own trade-off within the warehouse. S

Pallet orientation (short facing or long facing)

crucial aspect of warehouse layout

aisle width

This can include changing from single-deep to double-deep racks, utilizing drive-in racking, narrow aisle racking or introducing articulated forklift trucks which can operate in narrower aisles.

Change the type of storage medium or mechanical handling equipment used.

Unless stock items have different best-before codes, batch numbers or expiry dates it is worth checking how many part pallets there are of certain items and spending time consolidating them. This does require the use of labour but the trade-off is between the freeing up of additional space and this cost.

Consolidation of stock.

In circumstances where the warehouse height is reasonably low, where products and packaging are robust and budgets are tight, this type of storage is the most common method of storing large quantities of single SKU products.

Block stacking

Typical products stored in this way include white goods such as washing machines and refrigerators, kegs and barrels, cans and bottles.

Block stacking

Sufficient space needs to be allocated for forklift trucks to access each stack. Also, in order to access the bottom pallet you need to move the pallets above.

Access

The items at the bottom can be crushed by the weight of the items above

Damage

Unless product can be accessed at both ends of the stack, items can only be despatched on a LIFO (last in, first out) basis

Stock rotation

Utilization can be very poor if stock does not move quickly through the warehouse

Space utilization

This racking is present in the majority of warehouses worldwide. It is the most versatile of any racking without the need for any specialized handling equipment.

Wide aisle or selective pallet racking

allows pallets to be stored two deep in the racking thus eliminating an aisle

Double-deep pallet racking,

utilizes APR and provides storage for greater concentration of pallets by reducing the aisle width to circa 1.6 metres.

Narrow aisle racking

provides a safe and efficient equivalent to block stacking for loads that are too fragile or unstable to be stacked on top of each other.

Drive-in racking

driven by gravity

Pallet-flow racking

It is perfect for fast-moving product with FIFO stock rotation.

Pallet-flow racking

work by placing pallet loads on a series of nesting carts fed forward by gravity on rigid structural steel rails

Push-back systems

Where floor space is very expensive, a warehouse can be made very compact if the units of racking are movable by being mounted on rollers.

Mobile racking

similar to drive-in racking. However, it is operated by placing shuttles at the front of the racking, utilizing counterbalance, reach or narrow aisle trucks, depending on the height of the racking.

satellite system

The shuttles are controlled remotely via a radio frequency (RF) battery-operated control system and special channel rails.

satellite system

can buffer, sort, and stage palletized unit loads in exact loading sequence.

ACTIV System

These consist essentially of massive blocks of racking, built as an integral structure to a high degree of precision, and often acting as a support for the building’s roofing and wall cladding

Very high bay warehouses

ideal solution for long or heavy items such as pipe storage, timber, carpet or furniture storage

Cantilever racking

Typical areas are above the inbound and outbound loading bays.

Mezzanine floors/raised storage areas

It is a cost-effective piece of equipment to move pallets across short distances.

Hand pallet trucks

These are battery operated and are used for loading, unloading, picking and pallet-transfer duties to and from the receiving and despatch areas

Powered pallet trucks

These are utilized where distances between points within the warehouse are long and there is a requirement to move a number of pallets at the same time.

Tow tractors/tugs

These trucks are used for moving pallets around the warehouse and when required can lift pallets up to 5 metres.

Pallet or ‘Walkie’ stacker

most common trucks to be found in a warehouse.

Counterbalance forklift trucks (CBT)

These trucks are ideal for working within narrower aisles.

Reach trucks

These trucks are designed to operate with little more aisle space than their own width.

Narrow aisle or turret trucks

This system utilizes fixed path cranes to collect pallets at the front of the racking system and transport them to empty locations within the racking.

Automated storage and retrieval systems (AS/RS)

used for retrieval from double-deep racking and for the movement of large pallets;

extended forks:

used for picking up heavy bags, etc

crane attachment:

used for picking up loads with a central coil, eg tyres, carpets

boom attachment:

used for moving drums and barrels;

drum grip and clamps:

used for moving or tilting items;

load clamps:

used for lifting or moving large boxes or white goods

carton clamps:

used for moving and lifting paper reels

rotating paper roll clamps:

ability to move two pallets at the same time;

double pallet handlers:

load push/pull mechanism for moving product from a slip sheet onto a pallet.

slip sheet attachments:

an important step in protecting your workforce and your business as well as complying with the law. It helps you to focus on the risks that really matter in your workplace, ie the ones with the potential to cause harm.

risk assessment

Walk around the warehouse, internally and externally, and look at what could reasonably be expected to cause harm

Identify the hazards

For each hazard you need to be clear about who might be at risk and potentially harmed; it will help you to identify the best way of managing the risk.

Decide who might be harmed and how

Putting the results of your risk assessment into practice will make a difference when looking after people and your business.

Implement your findings and record and communicate them

Remember, prioritize and tackle the most important things first. As you complete each action, tick it off your plan.

Clear signage

often cause work-related problems, including back pain and neck pain

Manual handling

particular risk in the warehousing and storage industry, and any working at height must be properly planned, supervised and carried out in as safe a manner as possible.

Working at height

what are two major parts of legislation within the UK which relate directly to the operation of warehouse equipment?

1. Provision and Use of Work Equipment Regulations, 1998 (PUWER 1998) 2. The Lifting Operations and Lifting Equipment Regulations 1998 (LOLER)