Warehouse Design & Layout

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Warehouse Design & Layout

- Perancangan Fasilitas pada Warehouse-

Oleh : Debrina Puspita Andriani, ST., M.Eng Teknik Industri, Universitas Brawijaya

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Mission of A Warehouse ²

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Jaringan Distribusi dan Warehouse

•  PERSEDIAAN

! penyeimbang dan penyangga akibat adanya

perbedaan antara perencanaan produksi dengan permintaan aktual

•  KONSOLIDASI BARANG

! penggabungan barang- barang dari beberapa pabrik atau gudang kecil sebelum dikirimkan

•  DEPO

!Gudang penyangga yang mendekati pasar, untuk

mempercepat respon supply

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Main Functions in the Warehouse

Receiving and shipping (penerimaan dan pengiriman)

Identifying and sorting (pengidentifikasian dan penyaringan) Dispatching ke penyimpanan

Picking the order (pemilihan pesanan) Storing (penyimpanan)

Assembling the order ( perakitan pesanan) Packaging (pengemasan)

Dispatching the shipment

Maintaining record (perawatan produk)

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RECEIVING & SHIPPING

OPERATIONS ₅

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Typical warehouse functions and flows ⁶

Receiving Cross-docking Shipping

Reserve storage and pallet picking

D ire ct put a w ay to re se rve

Case Picking Broken Case Picking

Accumulation sortation packing and utilization

Replenishment Replenishment

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Receiving & Shipping Operations (1) ⁷

The Flow of Material

R S R S R S

Highway or Railroad

1.  Transportation facilities on one side

of building

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Receiving & Shipping Operations (2) ⁸

The Flow of Material

R S R S

R

S

2.  Transportation facilities on two

adjacent sides of building

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Receiving & Shipping Operations (3) ⁹

The Flow of Material

R S

R

S

R

S

Highway or Railroad

3.  Transportation facilities on two

opposite sides of building

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Receiving & Shipping

Space Planning ¹⁰

Determine what is to be 1 received and shipped

Determine the 2 number and type

of docks

3 Determine the space

requirements for the

receiving and shipping

area within the facility

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Receiving & Shipping Space Planning ¹¹

1. Determine what is to be received and shipped

Company( Date( Raw(Materials( Finished(Goods(

Prepared(by( Sheet( of( Plant(Supplies(

1( 2( 3( 4( 5( 6( 7( 8( 9( 10( 11(

DescripGon( Unit(Loads( Size(of(

Shipment(

(unit(loads)(

Frequency(

of(Shipment(

TransportaGon( Material(Handling(

Type( Capacity( Size( Weight( Mode( SpeciﬁcaGons( Method( Time(

(( (( (( (( (( (( (( (( (( (( ((

Receiving & Shipping Analysis Chart

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Receiving & Shipping Space Planning ¹²

2. Determine the number and type of docks

The number of docks

Waiting line analysis

Poisson distribution or

Simulation

Determine the time required to load or unload a

carrier

Time study : work sampling,

PMTS, etc.

Type of Docks

Rail docks Truck docks Drive in

docks 90 ⁰ docks

Finger

docks

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M in imu m M an eu ve r for R /S Area

13 Jenis Alat Material Handling Minimum Maneuvering Allowances (ft)

Tractor 14

Platform truck 12

Forklift 12

Narrow aisle truck 10

Hand-lift (jack) 8

Four-wheel hand truck 8

Two-wheel hand truck 6

Manual 5

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Receiving & Shipping Space Planning ¹⁴

3. Determine internal receiving and shipping area requirements

Personnel convenience/offices A receiving hold area Trash disposal & recycling

bins Pallet and packaging material storage/palletizing equipment

The truckers’ lounge Buffer or staging area Material handling equipment maneuvering

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DOCK LOCATIONS

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Lokasi dan Layout Dock ¹⁶

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Dock operations planning ¹⁷

As the interface between a dock at a given height and

variable-height carriers

Dock Levelers

As the interface between a fixed

dock and a moveable carrier

Bumper Pads

As the interface between a heated/

air conditioner dock and an unheated/non-air- conditioned carrier

Dock Shelters

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Modular design of storage/warehouse

facilities with expansion alternatives ¹⁸

1 2

3 Material flows

Expansion directions

(Receiving and shipping

activities)

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STORAGE OPERATIONS ₁₉

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Storage Medium

•  Stacking Frames

•  Cantilever Racks

•  Selective Rack

•  Flow Rack

•  Racks for Automated Storage and Retrieval System (AS/

RS)

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Stacking Frames ²¹

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Cantilever Racks

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Selective Rack ²³

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Flow rack ²⁴

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AS/RS (Automated Storage / Retrieval

Systems) ²⁵

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Storage and

Retrieval Systems

•  Person-to-item (fixed)

Rak penyimpanan statis (diam) dan orang/mesin yang mendatangi lokasi barang dan mengambilnya.

•  Item-to-person (random)

Barang yang berjalan dengan menggunakan material handling device (seperti conveyor) menuju lokasi penerimaan yang telah ditentukan. Flow rack merupakan salah satu media yang dirancang menggunakan sistem ini.

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Lokasi Gudang

•  Penentuan lokasi gudang yang didirikan merupakan permasalahan awal dan kritis dalam perancangan gudang.

•  Permasalahan berikutnya adalah berapa unit gudang yang harus dibangun serta luas dari tiap unit gudang tersebut.

•  Faktor yang harus dipertimbangkan dalam pembangunan gudang antara lain:

•  Lokasi Pelanggan/Pengguna,

•  Tingkat layanan yang diharapkan kepada pelanggan,

•  Harga tanah, biaya sewa, pajak, biaya konstruksi, dan asuransi.

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Layout Gudang Secara Umum

Layout gudang tergantung beberapa hal,

yaitu:

Barang yang disimpan

Luas lahan yang tersedia

Tinggi bangunan

Storage media yang

digunakan

S/R methods

Jalan/lintasan pada rak penyimpanan

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Layout Of

Warehouse Store

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Storage Layout Planning

Prinsip yang diperhitungkan dalam perencanaan gudang:

Popularity Frekuensi perpindahan

barang, masuk (receiving)

dan keluar (shipping)

Similarity Item yang

diterima dan dikirim

bersamaan, seharusnya

disimpan bersama

Size pengelompo

berdasakan kan ukuran fisik

barang

Characteristics Jenis dan sifat

barang yang disimpan

Utilisasi ruang termasuk luas lantai

storage kemudahan

akses

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Storage Policies

Randomized

storage policy Dedicated storage

policy Cube-per-order

index (COI) policy

Class-based storage

policy Shared storage

policy

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Penyimpanan barang berdasarkan Popularitas barang yang disimpan

•  Dirancangan berdasarkan hukum Pareto:

“80% the turnover will be as the result of 20% of material stored”.

•  Sehingga 20% material yang

menentukan tersebut dipertimbangkan untuk disimpan dan diambil dalam jarak yang paling pendek.

•  Barang yang masuk dalam kategori

fast moving diletakkan mendekati pintu masuk atau/dan keluar.

FA S T M O V IN G ITEM S M ED IU M M O V IN G ITEM S

S LO W M O V IN G ITEM S En tr an ce /Exi t

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“Optimum” Dedicated Storage Layout

190$180$170$160$150$140$130$120$110$100$100$110$120$130$140$150$160$170$180$190$

180$170$160$150$140$130$120$110$100$ 90$ 90$ 100$110$120$130$140$150$160$170$180$

170$160$150$140$130$120$110$100$ 90$ 80$ 80$ 90$ 100$110$120$130$140$150$160$170$

160$150$140$130$120$110$100$ 90$ 80$ 70$ 70$ 80$ 90$ 100$110$120$130$140$150$160$

150$140$130$120$110$100$ 90$ 80$ 70$ 60$ 60$ 70$ 80$ 90$ 100$110$120$130$140$150$

140$130$120$110$100$ 90$ 80$ 70$ 60$ 50$ 50$ 60$ 70$ 80$ 90$ 100$110$120$130$140$

130$120$110$100$ 90$ 80$ 70$ 60$ 50$ 40$ 40$ 50$ 60$ 70$ 80$ 90$ 100$110$120$130$

120$110$100$ 90$ 80$ 70$ 60$ 50$ 40$ 30$ 30$ 40$ 50$ 60$ 70$ 80$ 90$ 100$110$120$

110$100$ 90$ 80$ 70$ 60$ 50$ 40$ 30$ 20$ 20$ 30$ 40$ 50$ 60$ 70$ 80$ 90$ 100$110$

100$ 90$ 80$ 70$ 60$ 50$ 40$ 30$ 20$ 10$ 10$ 20$ 30$ 40$ 50$ 60$ 70$ 80$ 90$ 100$

D o c k

80%

15%

5%

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Rencana

Penyimpanan Berdasarkan Karekteristik Barang

Barang mudah busuk/tidak tahan lama, seperti ikan, sayur, buah, dll.

Media penyimpanan dirancang dengan temperatur yang khusus.

Barang yang berdimensi khusus/

tidak standar. Barang yang dimensinya tidak umum baik panjang ataupun luasannya. Sehingga memerlukan rak/

media simpan yang fleksible dari dimensi dan ketinggiannya.

Barang berbahaya/beracun, seperti cat, pernis, bahan kimia yang mudah

meledak, dll. Penanganan khusus terhadap barang ini diatur dalam regulasi safety dan harus menempati

lokasi yang aman dan terisolir.

Barang berharga/kecil. Penanganan barang yang mudah dicuri dan

bernilai tinggi harus

mempertimbangkan penjagaan dan lokasi penempatan yang aman.

Barang yang bersesuaian. Barang yang akan rusak jika ditempatkan berdekatan dengan barang

yang mempengaruhinya secara kimia /fisik.

Seperti margarin, jika disimpan diruang pendingin bersamaan dengan ikan, maka bau

ikan akan mempengaruhi/merusak aroma 34

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ORDER PICKING

OPERATIONS ₃₅

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36 Work$Element$ Method$of$Elimina<on$ Equipment$Required$

Traveling$

Bring(pick(locaGons(to(picker(

((

StockUtoUpicker(System(

U(Miniload(AS/RS(

U(Horizontal(Carousel(

U(VerGcal(Carousel(

Documen<ng$

Automate(informaGon(ﬂow(

((

Computer(Aided(Order(Picking(

AutomaGc(IdenGﬁcaGon(System(

LightUAided(Order(Picking(

Reaching$ Present(items(at(waist(level(

((

VerGcal(Carousel(

PersonUaboard(ASRS(

Miniload(ASRS(

Sor<ng$ Assign(one(picker(per(order(

and(one(order(per(tour( ((

Searching$ Bring(pick(locaGon(to(picker( StockUtoUpicker(System(

Take(picker(to(pick(locaGon( PersonUaboard(ASRS(

Illuminate(pick(locaGon( PickUtoULight(System(

Extrac<ng$

Automated(dispensing(

AutomaGc(Item(Pickers(

RoboGc(Order(Pickers(

Coun<ng$ Weigh(count( Scales(on(Picking(Vehicles(

Prepackage(in(issue(

increments(

Order Picking Work Elements &

Means for

Elimination

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Methods of Order Picking ³⁷

Procedure( Pickers(Per(

Orders( Line(Items(Per(

Pick( Period(Per(

Shi](

Discrete( Single( Single( Single(

Zone( MulGple( Single( Single(

Batch( Single( MulGple( Single(

Wave( Single( Single( MulGple(

ZoneUBatch( MulGple( MulGple( Single(

ZoneUWave( MulGple( Single( MulGple(

ZoneUBatchUWave( MulGple( MulGple( MulGple(

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REFERENCES

•  Tompkins, White, Bozer and Tanchoco. (2010). Facilities Planning (4th Ed.). New York: Wiley.

Warehouse Design & Layout