CHAPTER 9.
WAREHOUSE LAYOUT
Introduction
“Giving a man space is like giving a dog a computer: the chances are he
will not use it wisely” (Bette-Jane Raphael)
Eg: Warehouse design
CHAPTER 9. WAREHOUSE LAYOUT
Introduction
* Certain notes when designing the warehouse
. Gather as much data as possible and analyse it.
. Try to imagine the business in 5–10 years’ time and build in flexibility.
. Concentrate on the cubic capacity of the building.
. Ensure the design is sympathetic to the existing storage equipment and
MHE (if applicable).
. Put the health and safety of staff at the forefront of the design.
. Reduce the amount of movement required within the warehouse.
CHAPTER 9. WAREHOUSE LAYOUT
Introduction
* Certain notes when designing the warehouse
. Try to standardize the packaging both for movement and storage.
. Understand the local building regulations and floor loading
requirements.
. Don’t forget the outside of the building.
CHAPTER 9. WAREHOUSE LAYOUT
1. Data collection and analysis
* Data can be collected:
. The item and order profile
. The number of supplier deliveries per day
. The number of customer deliveries
. The average order size.
. The method for loading and unloading these vehicles.
CHAPTER 9. WAREHOUSE LAYOUT
1. Data collection and analysis
* The main floor-space areas within the warehouse that need
to be calculated are as follows:
. receiving area; quarantine and inspection area;
. reserve storage area; carton-picking area; item-pick area;
. value-adding services area; packing area; despatch area;
. cross-dock area; empty pallet and packaging storage area;
. MHE charging areas;
. warehouse offices; restrooms.
CHAPTER 9. WAREHOUSE LAYOUT
1. Data collection and analysis
* Certain notes to collect the data
. At present, history, and in the future
. Average volume, peak seasons.
. Fluctuations between days of the week
. The amount of space required for specific operations, and storage
equipment
CHAPTER 9. WAREHOUSE LAYOUT
2. Space calculations
* Receipt and dispatch areas
Formula:
Space = (number of loads × hours to unload) : Time of shift) × (number
of pallets × space per pallet)
Eg: if we receive 20 vehicles per day, 26 pallets per load with a pallet size
of 1.2 metres by 1.0 metres and it takes 45 minutes per load to unload
and 30 minutes per load to check and we operate an eight-hour shift:
per hour (75/60)
Pallet floor space = {round-up ((20 × 1.25) ÷ 8) × (26 × (1.2 × 1))} = 4
× 31.2 = 124.8 square metres
CHAPTER 9. WAREHOUSE LAYOUT
2. Space calculations
* Storage space
Calculating the storage space: the amount of items stored per product
line; the total of pallet; dimension of pallet, etc…
CHAPTER 9. WAREHOUSE LAYOUT
2. Space calculations
* Storage space
CHAPTER 9. WAREHOUSE LAYOUT
2. Space calculations
* Storage space
a formula to calculate the number of pallets that can be stored within a
given cubic area:
(Number of width modules × pallets in a module width) × (number of
length modules × pallets in module length) × number of height modules
where: Module width = width of aisle + 2 pallet lengths (short side) + clearance
between back-to-back pallets
Module length = width of upright + 3 × clearance + 2 pallets (long side)
Module height = height of pallet + clearance above pallet plus racking beam height
CHAPTER 9. WAREHOUSE LAYOUT
2. Space calculations
* Storage space
Certain factors that need to be taken into account are:
. Planned utilization within the warehouse.
. The presence and location of roof columns.
. The requirement for space between the backs of pallets (flue) and at the sides of
pallets.
. The presence and location of sprinklers (ceiling or in rack).
. The type of lighting utilized and any heating or cooling systems
. Lift height of forklift truck.
. Pallet orientation
. The requirement for cross aisles
. Type of racking
CHAPTER 9. WAREHOUSE LAYOUT
3. Aisle width
The aisle width is determined by the turning circle of the forklift truck
and the size of pallet being carried.
CHAPTER 9. WAREHOUSE LAYOUT
3. Aisle width
Deciding on the optimal aisle width is a critical part of an overall
storage/ materials-handling strategy. Aisle width decisions need to
achieve the best combination of productivity, space utilization, flexibility,
safety and equipment costs for the specific application (Piasecki 2002).
CHAPTER 9. WAREHOUSE LAYOUT
4. Other space
. Areas for packing, value-adding services and returns processing
. Store, recharge and change batteries or gas canisters for forklifts, a
parking area for equipment
. Park vehicles which are either collecting or delivering products;
. Sufficient turning circle for the largest vehicle;
. Waste storage and recycling areas;
. Areas for weather resistant packaging; parking for staff and visitor cars;
. Gas or diesel storage tanks
CHAPTER 9. WAREHOUSE LAYOUT
5. Warehouse layout example
CHAPTER 9. WAREHOUSE LAYOUT
6. Finding additional space
When facing a shortage of space within the warehouse there are a
number of options available:
. expanding the warehouse;
. renting additional space;
. creating more space within the existing premises.
CHAPTER 9. WAREHOUSE LAYOUT
6. Finding additional space
Some options with the existing warehouse:
. Change the type of storage medium or mechanical handling equipment
used.
. Consolidation of stock.
. Reducing beam heights within the warehouse to accommodate smaller,
full or part pallets.
. Moving from fixed locations to random locations.