1. Warehouse Operations

2. What is Warehouse ? อ้างอิงจาก http://www.wisegeek.com
A warehouse is a large building where goods are stored, and where they may be catalogued, shipped, or received, depending upon the type. Though in the past, many warehouses, often located in industrial areas sometimes next to major shipping ports, were teeming with workers, the modern warehouse may be either completely or totally automated depending upon how advanced the company is.

3. What is Warehouse ?
Warehouses have existed for several centuries, and the word itself is not hard to understand. “Wares” were the things possessed by a seller and to house these in a central location meant your were storing your wares.getting in new products, and shipping out products already stored.

4. What is Warehouse ?
Another important part of maintaining a good warehouse is keeping inventory of what products are presently in the warehouse, what has been shipped and what has been received.

5. Warehouse Functions Provide temporary storage Put together an order
Serve as a customer service facility
Protect goods
Perform value added services
Inventory

6. The Value Chain Firm Structure Human Resource Development
Supporting
Activities
Technology Development
Procurement
Inbound
Logistics
Operations
Outbound
Logistics
Marketing
and Sales
Services

7. Warehouse Functions - Warehouse organizes and repackages product
- Product arrives packaged on a large scale and leaves packages on a smaller scale
“The smaller the handling unit, the greater the handling cost”

8. Processes of reorganization of product
Inbound Processes
Receiving
Put away/Storage
Outbound Processes
Processing customer orders
Order-picking
Checking
Packing
Shipping

9. Receiving Unloading and staging for put away
Inspection (Sampling and/or 100%)
Scanned for registering to
Confirm its availability
Confirm ownership
Normally, receiving is accounted for about 10% of W/H operations cost.

10. Put-away
“Before product can be put away, an appropriate storage location must be determined”
“Where the product is stored is directly related to how quick and what cost to retrieve it later”

11. Put-away W/H manager must know at all time that:
Which storage locations are available
How large they are
How much weight they can take
After product is put away, its location must be recorded
Cost of put away is about 15% of W/H operating expenses

12. Process of customer orders
On receipt of customer orders the warehouse must perform checks such as to verify that inventory is available to ship
The warehouse must produce a “pick list” to guide the order picking
The order picking include assigning operators and sequence of order picking and shipping

13. Order Picking
Order picking account for 55% of warehouse operations cost, it can be broken down to:
Traveling 55%
Searching 15%
Extracting 10%
Paper work and other 20%
*% of total order picking cost

14. Order Picking Depend on type of storage and retrieval system
Person-to-item
Item-to-person
Manual or ASRS
Terminology used in order picking operations
Pick-sheet or pick line
Pick/visit
Pick face
Pick density (# of picks per foot of travel)

15. Order Picking Flow time is a main indicator for picking performance
Short flow time can lead to better service and responsiveness
Flow time depend on
how large the unit load, serial or parallel pickers
Number of pickers

16. Order Picking
If the total work to pick and load a truck is small, one picker may be assign to each order
If the orders to pick and load are large or span distant region, several pickers are needed to shorten the flow time

17. Order Picking
For a warehouse that move a lot of small products for each of many customers, such as shipping to retail stores, order picking may be organized as an assembly line
The assembly line needs to be balance using some line balancing techniques

18. Checking and Packing Packing can be very labor intensive
Every item needs to be handled but with minimal walking
Then, checking can be performed simultaneously to make sure completeness of order
Incomplete order leads to return which is expensive

19. Checking and Packing
Packing must aim at minimizing broken space when shipping
Also, customers want orders in as few containers as possible to avoid excessive handling cost

20. Shipping Shipping generally handles larger units than picking
Less labor intensive
Goal is to
minimize transportation cost
Protect goods
Ease load and unloading

21. Warehouse Management Systems
-Highly automated system that runs day-to-day operations of a DC
-Controls item putaway, picking, packing, and shipping
-Features
transportation management
order management
yard management
labor management
warehouse optimization

22. A WMS

23. Vendor-Managed Inventory
Manufacturers generate orders, not distributors or retailers
Stocking information is accessed using EDI
A first step towards supply chain collaboration
Increased speed, reduced errors, and improved service

24. Warehouse Management System (WMS)
The main function of WMS are to track all product arriving and shipping out
It most fundamental capability is to record receipt of inventory into the warehouse and register its shipment out (including financial transaction)

25. Warehouse Management System (WMS)
Another important function are:
Ability to do storage allocation
Routing of material handling equipment
Track every place that product can be stored
Known as stock locator system

26. Manu Features of WMS Basic features Appointment scheduling Receiving
Quality assurance
Put away
Location tracking
Work-order management
Picking
Packing and consolidating
Shipping

27. Manu Features of WMS High-end features Cycle counting Replenishment
Yard management
Labor management
Value-added service
Etc.

28. Manu Features of WMS
WMS’s are extending their functionality to support activities in supply chain both upstream and downstream like:
EXE technologies
Manhattan Associates
MARC Global System
Swisslog Software
etc

29. Materials Handling

30. Materials Handling
Material handling is an activity that uses the right method to provide the right amount of the right material at the right place, at the right time, in the right sequence, in the right position and at the right cost

31. Materials Handling (Cont)
Systems perspective
20-70% of product cost attributed to material handling

32. Unit Load
Unit load - number of items or bulk material arranged so they can be picked up and delivered as one load
Large or small?
If large, cost/unit handled decreases
But, depending upon
cost of unitizing, de-unitizing

33. Unit Load (Cont) smaller unit load may be desired
space required for material handling
material handling carrier payload
work-in-process inventory costs
storage and return of empty pallets or containers used to hold the unit load
smaller unit load may be desired

34. Unit Load (Cont) Seven steps to design a unit load
Unit load concept applicable?
Select the unit load type
Identify most remote source of load
Determine farthest practicable destination for load

35. Unit Load (Cont) Establish unit load size
Determine unit load configuration
Determine how to build unit load

36. Material Handling Device Types
Conveyors
Palletizers
Pallet Lifting Devices
Trucks
Robots

37. Material Handling Device Types (Cont)
AGVs
Jibs, Cranes and Hoists
Warehouse MHSs

38. Conveyors
Accumulation
Belt
Bucket
Can
Chain

39. Conveyors (Cont) Chute Gravity Pneumatic or vacuum Power and free
Roller

40. Conveyors (Cont)
Screw
Skid
Slat
Tow line
Trolley
Wheel

41. Trucks Hand truck Fork-lift truck Pallet truck Platform truck
Counterbalanced truck
Tractor-trailer truck
AGV

42. Robots Point-to-point Contouring or continuous path
Walkthrough or teach
Lead through or teach pendant
Hydraulic
Servo-controlled

43. MHSs in Action Europe Combined Terminals (ECT)
ECT - one of largest in world and largst in Europe
Goods shipped from and to Europe
Built on reclaimed land in the North Sea
Large and Small containers

44. MHSs in Action (Cont) Trucks wait to be off-loaded by straddle carrier
Carrier takes container to holding area
Shipped in approximately 2 days
Mobile gantry cranes on tracks deposit containers in forward area

45. MHSs in Action (Cont)
Mobile gantry cranes hold containers in top four corners and deposit on waiting AGVs
Fleet of AGVs in forward area take containers to tower cranes
Tower cranes deposit load on ship bed
Procedure reversed for off-loading ship

46. AGVs Classification of MHS
Synchronous systems
Asynchronous systems
Synchronous systems, e.g. conveyors, used in continuous processes or heavy traffic, discrete parts environments

47. AGVs (Cont)
Asynchronous systems, e.g., AGV, AS/RS, fork-lift trucks, monorails, cranes and hoists used in light traffic, discrete parts environments when material handling flexibility desired

48. Design and Control Problems in AGVSs
Material flow network
Location of pick-up/drop-off (P/D) points
Number and type of AGVs
AGV Assignments to material transfer requests
AGV routing and dispatching

49. Design and Control Problems in AGVSs (Cont)
Strategies for resolving route conflicts, so AGV throughput rate is maximized, an other costs (purchase, maintenance and operating costs of AGVs, computer control devices, and the material flow network, as well as inventory costs and production equipment idle costs incurred due to excessive material transfer and wait times), are minimized