2. The design of storage and handling facilities
Chapter 11
The design of storage and handling facilities

3. Overview This chapter covers the following topics: Introduction
Initial requirements
Sizing the warehouse
Operation and warehouse management systems (WMS)
Design process
Fire
Security
Lighting

4. Introduction
Need to understand the principles of the layout of a facility
Allows change that is efficient
Introduces the principles of change or mere expansion
Ongoing changes to a facility requiring adaptation and improvement
The design for a new facility is specialised and beyond this text

5. Design requirements Should be written and reviewed before any change
Purpose needs to be explicitly defined:
- Cross dock
- Manufacturing storage warehouse
- Distribution centre (and so on)
Growth forecast
Sets the size of any change to cater for the future
Purpose of a facility is defined by a PPC

6. Operations and WMS
Define the methods supported by the warehouse management system (WMS) and what is most efficient for the operation.
Chart the processes.
Identify limitations.
Find solutions that are permitted and suit the operation.

7. Design process Identify PPCs in the products and processes
For each PPC, record:
- Storage requirements
- Handling and moving areas
- Assembly areas for transport loading and unloading
Receiving requirements

8. PPC combination and optimisation
Define for each PPC:
- Which areas are unique to the PPC
- Which areas can be combined and the impact on space or congestion
Periods of operation

9. Common areas
If common areas are used in same period, then require increased space above single use, but less than proportion to number of PPCs that will use space.
Example: a travel aisle for two PPCs need only be 50% wider than that required for one PPC use.

10. Aisle sizes between/around racks
Aisle size is determined by equipment used and traffic .
Rack volume to total floor space is important to know, as directly influences quantity of product to be stored – must be able to calculate this.

11. Methods – receiving
Interaction between receipt and put-away determines size of receiving area.
Disciplined placing in lines at all times makes for smaller size.
Partial receipt before put-away begins reduces size necessitated by receiving area.

12. Layout of receiving bay

13. Movement zones
Defined to cater for all movement that will occur, reflecting:
Number of PPCs that will use it concurrently (defined by periods of use)
Speed of equipment
Turning and stopping
Flows – one- or two-way increase the size of movement area

14. Other requirements Pick method Loading/unloading doors
External truck area

15. Combining areas Requirements for each PPC
Can use CAD or drawing method
Drawing method:
- Record areas on paper layouts (cut out)
- Move around on drawing of facility
- Unique areas must be allocated so temperatures are graded from lowest to highest and flows are sensibly minimised
Common areas must be combined

16. Other issues
Fire
Safety
Security
Lighting