Warehouse Design & Layout

(1)

Warehouse Design & Layout

- Perancangan Fasilitas pada

Warehouse

-

Oleh :

Debrina Puspita Andriani

(2)

Outline

Warehouse

Receiving

& Shipping

operations

Dock

locations

Storage

operations

Order

picking

operations

2

(3)

(4)

Jaringan Distribusi dan

Warehouse

• PERSEDIAAN

à

penyeimbang dan

penyangga akibat adanya

perbedaan antara perencanaan

produksi dengan permintaan

aktual

• KONSOLIDASI BARANG

à

penggabungan

barang-barang dari beberapa pabrik

atau gudang kecil sebelum

dikirimkan

• DEPO

àGudang penyangga yang

mendekati pasar, untuk

mempercepat respon supply

(5)

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

(perawatan produk)

Maintaining record

(6)

Warehouse Functions

Provide temporary storage of goods

Put together customer orders

Serve as a customer service facility

Protect goods

Segregate hazardous or contaminated materials

Perform value-added services

(7)

(8)

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

8

(9)

Warehouse

Design

9 •  Location

•  How many?

•  Where?

•  Capacity

•  Overall Layout

(10)

RECEIVING & SHIPPING

(11)

Typical warehouse functions and flows

11 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

(12)

Receiving & Shipping Operations (1)

12 The Flow of

Material

R

S

R

S

R S

Highway or Railroad

1. Transportation facilities on one side

(13)

Receiving & Shipping Operations (2)

13 The Flow of

Material

R

S

_{R S}

R

S

2. Transportation facilities on two

(14)

Receiving & Shipping Operations (3)

14 The Flow of

Material

R

S

R

S

R

S

Highway or Railroad

3. Transportation facilities on two

(15)

Receiving & Shipping

Space Planning

15

1 Determine what is to be

received and shipped

2 Determine the

number and type

of docks

3 Determine the space

requirements for the

receiving and shipping

area within the facility

(16)

Receiving & Shipping Space Planning

16 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 Shipment Size of (unit loads)

Frequency of Shipment

TransportaGon Material Handling Type Capacity Size Weight Mode SpeciﬁcaGons Method Time

(17)

Receiving & Shipping Space Planning

17 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

(18)

M

in

imu

m

M

an

eu

ve

r

for R

/S Area

18 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

(19)

Receiving & Shipping Space Planning

19 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}

(20)

DOCK LOCATIONS

(21)

(22)

Dock operations planning

22 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

(23)

Modular design of storage/warehouse

facilities with expansion alternatives

23

1

2

3 Material flows

Expansion directions

(Receiving and shipping

activities)

(24)

(25)

Storage Medium

• Stacking Frames

• Cantilever Racks

• Selective Rack

• Flow Rack

• Racks for Automated Storage and Retrieval System (AS/

RS)

(26)

(27)

Cantilever Racks

(28)

(29)

(30)

AS/RS

(Automated Storage / Retrieval

(31)

Storage and

Retrieval Systems (1)

• 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.

(32)

Storage and

Retrieval Systems (2)

PELAJARI :

• Manual S/RS

• Semi-automated S/RS

• Automated S/RS

• Aisle-captive AS/RS

• Aisle-to-aisle AS/RS

• Storage Carousels

• Vertical

• Horizontal

• Miniload AS/RS

• Robotic AS/RS

• High-rise AS/RS (two motors)

(33)

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

kan

berdasakan

ukuran fisik

barang

Characteristics

Jenis dan sifat

barang yang

disimpan

Utilisasi

ruang

termasuk

luas lantai

storage

kemudahan

akses

33

(34)

Storage Policies

Randomized

storage policy

Dedicated storage

policy

index (COI) policy

Cube-per-order

Class-based storage

policy

Shared storage

policy

(35)

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

O

V

IN

G

ITEM

S

LO

W

M

O

V

IN

G

ITEM

S

En

tr

an

ce

/Exi

t

35

(36)

“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%

36

(37)

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

(38)

ORDER PICKING

WAREHOUSE

(39)

39 Work Element

Method of Elimina<on

Equipment Required

Traveling

Bring pick locaGons to picker

Stock-to-picker System

- Miniload AS/RS

- Horizontal Carousel

- VerGcal Carousel

Documen<ng

Automate informaGon ﬂow

Computer Aided Order Picking

AutomaGc IdenGﬁcaGon System

Light-Aided Order Picking

Reaching Present items at waist level

VerGcal Carousel

Person-aboard ASRS

Miniload ASRS

Sor<ng

Assign one picker per order

and one order per tour

Searching

Bring pick locaGon to picker Stock-to-picker System

_{Take picker to pick locaGon Person-aboard ASRS}

Illuminate pick locaGon

Pick-to-Light System

Extrac<ng

Automated dispensing

AutomaGc Item Pickers

RoboGc Order Pickers

Coun<ng

Weigh count

_{Prepackage in issue}

Scales on Picking Vehicles

increments

Order

Picking

Work

Elements &

Means for

Elimination

(40)

Methods of Order Picking

40 Procedure

Pickers Per

_Orders

Line Items Per

_Pick

Period Per

_Shi]

Discrete

Single

Zone

MulGple

Single

Batch

Single

MulGple

Single

Wave

Single

MulGple

Zone-Batch

MulGple

Single

Zone-Wave

MulGple

Single

MulGple

(41)

REFERENCES

• Tompkins, White, Bozer and Tanchoco. (2010). Facilities

Planning (4th Ed.). New York: Wiley.