1. Poor layout and product flow (in and out)
A poor warehouse layout locks in poor productivity and what’s worse is that it becomes invisible. Because businesses change over time, a once perfectly suitable layout and racking arrangement can become a drain on productivity. Perhaps the layout was never planned in the first place but racking was simply put wherever it fitted at the time the installer showed up.
The principles of process design dictate
that the design of the supporting systems and infrastructure must support the
business process. So in order to get the
layout correct you must first design the process that you want it to support -
with full knowledge of what is possible.
This is the approach we take to all our warehouse designs – first the
process then the layout and systems to support it.
Many people make the mistake of starting
with the current system and the existing infrastructure and then designing a
process around that. Unfortunately when
you do it this way, you are accepting your current limitations without question
and missing the opportunity to unleash greater overall productivity in your
business. What often starts as a need
for some new racking, or an observation that you are running out of space in
your warehouse can be an opportunity for a major reform and productivity gain
if you open your eyes to what is possible.
The basic principles of efficient warehouse
layout are as follows
1.
Keep fast moving product in the fastest to
access areas. The corollary also
applies, put slow moving items in the slowest to access storage areas.
a.
If you have a bad building with pillars and
walls in all the wrong places then this idea is what will bring back the
productivity into your operations. Many
businesses simply do not apply this principle to their warehouses or do not
apply it rigorously enough to get the full benefit.
2.
Use fixed pick locations near to the despatch
dock with a periodic replenishment cycle.
This keeps fast moving products close together to reduce travel path.
a.
This requirement must be balanced by the need to
allow sufficient access to the pick face so that all of the orders for fast
moving product may be picked. Too close
together and you can create crowding as too many pickers need to access the
same product at the same time.
3.
Store the balance of fast moving stock in
randomly located bulk storage racks.
a.
As per point 1: in bulk storage racks, keep the
faster moving products in the fastest to access locations, which, in pallet
racking, will be low and nearest to the despatch dock.
These first
three points are related to the idea that is commonly called product slotting. They are important to layout because they will
impact what type of racking you put in your fast zone. We will talk more about slotting in mistake
number 15.
4.
Build travel shortcut aisles into long runs of
racking or shelving so pickers can cut across aisles to reduce travel path.
a.
Pallet racking should be continuous with beams
removed in one rack bay to a sufficient height to let your forklifts travel
underneath the higher levels.
5.
Maximise the use of the building volume with
high level pallet racking, multi-level shelving modules and mezzanine levels.
a.
Generally you can stack stock to up to 45cm
below the level of your sprinkler heads but check with your fire system
maintenance provider for the clearance required for your particular
installation.
6.
Eliminate air – your stock does not need to
breathe!
a.
When I walk into a warehouse, one of the first
things I look for is storage density as indicated by the amount of free space
(air) around products in the storage racking.
Lots of air means lots of wasted space which means higher storage cost
per unit, longer travel path for put-away and picking and poor productivity.
b.
Once you realise that an investment in the most
appropriate racking and storage systems for your products is an offset of both
rent and operating expense you will not quibble over the cost anymore. Good racking and storage systems make you
money, last indefinitely and are never superseded. Is any other investment this good? (Maybe
real estate!)
7.
Build optimised workstations for receiving, packing
and despatching orders near the inbound and outbound docks.
a.
Too much focus just on the pick process and
neglecting the whole of the warehouse operations will see you missing out on
valuable productivity gains. However
your stock comes in or goes out, you need space and efficient process to get it
into or out of the warehouse.
b.
This means a well laid out operations bench
which is kept clear of junk and has everything you need to hand such as labels,
packing materials, paperwork, computer workstation (if required) & printers.
8.
Allow sufficient staging space for inbound and
outbound order staging and processing.
a.
Around the workstations and at each dock you
need clearance for staging of product in and out. Nothing kills productivity and throughput
rates faster than the double handling caused by inadequate staging space.
9.
Principles of good warehouse layout must be
applied as part of the overall operational process design. This includes the
warehouse management system, data collection technology (mobile terminals with
barcode scanners, voice directed task technology), racking systems and
materials handling equipment.
This is post is taken from an ebook that is now available as a bonus to members of the Warehouse Performance Initiative (WPI*).
The WPI is a place for learning how to improve your knowledge of warehouse operations improvement, sharing skills and ideas and helping other warehouse professionals. Joining the WPI will give you access to a growing range of free and premium content which will have a direct impact on improving your warehouse performance when you apply it to your business.
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