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Warehousing Equipment

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Title: Warehousing Equipment


1
Warehousing Equipment
  • Tompkins et al., Facilities Planning, John
    Wiley Sons, 1996 Chapters 6, 9
  • College-Industry Council on Material Handling
    Education Material Handling Equipment Taxonomy
    http//www.mhia.org/et/mhe_tax.htm

2
The role of equipment in warehouse operations
  • Reduce cost (labor space)
  • enhance space utilization by, e.g.,
  • enabling the exploitation of the vertical
    dimension of the facility
  • allowing for denser packing
  • allow for more efficient order-picking by, e.g.,
  • increasing the sku density
  • supporting the automated transfer of material
    from storage to sorting and consolidation area
  • Enhance responsiveness
  • increase the throughput of the facility, e.g.,
  • increasing the sku density
  • establishing a more ergonomic environment/arrangem
    ent for the warehouse operators
  • facilitating the parallelization of order picking
  • by parallelizing the tasks of order-picking and
    replensihment

3
The role of equipment in warehouse operations
(cont.)
  • Maintain Quality of Product and Operations
  • provide an orderly storage environment
  • provide efficient ways for product tracing and
    identification
  • provide safe and secure material handling
  • facilitate order sortation and consolidation
  • establish and maintain a controlled environment
    e.g.,
  • temperature control
  • access control

4
Equipment Classification(Tompkins et. al., pgs
170-173)
  • Containers Unitizing Equipment
  • Storage and Retrieval Equipment
  • Unit Load
  • Small Load
  • Conveyors
  • Warehouse docks and dock-related equipment
  • Automatic Identification and Communication
    Equipment

5
For detailed functional descriptions, discussion
on supported efficiencies, and pictures
  • College-Industry Council on Material Handling
    Education Material Handling Equipment Taxonomy
    http//www.mhia.org/et/mhe_tax.htm
  • Tompkins et al., Facilities Planning, John
    Wiley Sons, 1996 Chapters 6, 9

6
Pallet Storage Modes
  • Block Stacking
  • Rack Storage
  • Single-Deep
  • Double-Deep
  • Drive-In/Through
  • Pallet Flow
  • Unit Load AS/RS
  • etc.

7
Block Stacking (or Floor Storage)
Lane Height
Lane Depth (3-deep)
Lanes
  • An efficient storage mode when
  • there are multiple pallets per SKU
  • inventory is turned in large increments, I.e.,
    several loads of the same SKU are received or
    withdrawn at one time.
  • Main problems
  • Loss of space due to honeycombing
  • not effective utilization of the vertical
    dimension of the facility

8
Selective or Single-Deep or Simple Pallet Rack
  • The benchmark storage mode
  • Due to rack supports, each pallet is
    independently accessible (i.e. it supports
    totally random access)
  • Trade-off too many aisles gt inefficient space
    utilization

9
Double-deep rack
  • Two selective racks placed back-to-back gt 2-deep
    lanes
  • Each lane dedicated to one SKU gt space loss in
    case of SKUs with odd number of pallets
  • Less aisle space required (upto 50 savings in
    aisle space)
  • Trade-off More work and/or specialized equipment
    for retrieving

10
Other pallet rack types
  • Drive-In/Through rack 5-10 loads deep
  • Better space utilization
  • More difficult, even dangerous retrieval
  • Pallet flow rack up to 8 pallets deep
  • The rack shelves are slanted and have rollers,
    and therefore, every time a pallet is retrieved
    from a lane, the pallet behind it takes its
    position.
  • Allows for simultaneous picking and restocking
  • Supports FIFO operation
  • Typically used in high-throughput facilities
  • Cantilever rack
  • Supports long items like timber and pipes

11
Unit-Load Retrieval Equipment
  • Key Differentiation factors
  • aisle width requirements
  • lift height/weight capacity
  • Lane depth they can reach
  • degree of automation
  • capital expense
  • Major types
  • Walkie Stacker
  • Counterbalance Lift Truck
  • Narrow Aisle Vehicles
  • Automated Storage/Retrieval Machines

12
Small Load Storage and Retrieval Equipment
  • Operator-to-Stock (or Man-to-Part or
    in-the-aisle) system the operator travels to the
    storage location to retrieve material
  • Stock-to-Operator (or Part-to-Man or
    end-of-aisle) system the material is
    mechanically transported to the operator for
    retrieval
  • Advantages of STO
  • higher productivity
  • easier supervision
  • better item security and protection
  • Disadvantages of STO
  • more expensive
  • more maintenance
  • more difficult to reconfigure

13
Operator-to-Stock Storage Equipment
  • Bin Shelving
  • Modular Storage Drawers in Cabinets
  • Carton Flow Racks
  • Mobile Storage
  • All the above equipment can also be arranged in
    mezzanines to get a better exploitation of the
    building cube.

14
Operator-to-Stock Retrieval Equipment
  • Picking Cart
  • Order Picker Truck (for higher placed loads)
  • Person-aboard Automated Storage/Retrieval Machine
  • captive aisle
  • free roaming
  • (Robotic Retrieval)

15
Stock-to-Operator Equipment
  • Carousels
  • Horizontal
  • Vertical
  • Independently Rotating Racks
  • Miniload Automated Storage and Retrieval Machine
  • Automatic Dispenser
  • Productivity gains
  • Allow for extensive parallelization of order
    retrievals
  • Focus on extracting rather than traveling and
    searching

16
Conveyors
  • (Flat) Belt
  • Roller
  • Telescoping Belt
  • Chute
  • Sorting
  • Deflector
  • Push Diverter
  • Pop-up Skewed Wheels
  • Pop-up Roller
  • Tilt tray
  • Remarks
  • Conveyors change the economics of travel.
  • They can partition physically the warehouse into
    zones

17
Warehouse docks and dock-related equipment
  • Warehouse docks The facility interface with the
    shipping carriers
  • Dock configurations and dimensioning

18
Equipment facilitating the interfacing between
docks and shipping carriers
  • Dock levelers compensate the height difference
    between the carrier platform and the dock door
  • mobile yard ramps
  • permanent adjustable dock boards
  • truck levelers
  • scissors-type lifting docks
  • Bumper pads absorb the shock from the impact of
    the shipping trailer with the dock walls
    (laminated rubber cushions)
  • 40,000 lb load traveling 4 mph gt 150,000 lb
    force
  • Dock shelter a flexible shield that when engaged
    to the carrier provides a closed-environment
    interface between it and the inner area of the
    warehouse
  • energy savings, increased safety, product
    protection, etc.

19
Automatic Identification and Communication
Equipment
  • Permits real-time, nearly flawless data
    collection and communication, and therefore, it
    facilitates and increases the real-time awareness
    of the location, amount, origin, destination and
    schedule of the material.

20
Automatic Identification and Recognition
  • Bar coding technology
  • bar codes
  • bar code readers
  • bar code printers
  • Optical character recognition
  • Radio Frequency (RF) and Surface Accoustical Wave
    (SAW) tags
  • Magnetic Stripes
  • Machine Vision

21
Automatic Paperless Communication
  • RF data terminal
  • Voice headset
  • Light and Computer Aids
  • Smart card
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