Warehouse & Distribution Science - gatech.edu

1 Warehouse & Distribution SCIENCER elease for the latest version J. BARTHOLDI, III1 Steven T. HACKMANThe Supply Chain and Logistics InstituteSchool of Industrial and Systems EngineeringGeorgia Institute of TechnologyAtlanta, GA 30332-0205 USAR evised August 19, 20141 Copyrightc 1998 2014 John J. BARTHOLDI, III and Steven T. HACKMAN. All rightsreserved. This material may be freely copied for educational purposes but not for resale aslong as the authors names and the copyright notice appear clearly on the copies. this book .. first..ivI Issues, equipment, processes11 Warehouse have a Warehouse ?.. of warehouses..82 Material fluid model of product flow.. of handling.. fundamental resources.. : Dedicated versus Shared .. Warehouse as a queuing system..203 Warehouse .

2 The work of order-picking.. and packing..3134 CONTENTS4 Warehouse management and shipping.. locator system.. of features.. market.. Chain Execution Systems..365 Storage and handling equipment.. storage.. or static rack.. flow rack.. equipment.. the lighter side..46II Layout476 Layout of a unit-load .. or stack?.. depth.. labor by dual-cycle operations.. labor by careful product placement.. of receiving and shipping.. configuration..707 Layout of a carton-pick-from-pallet for a forward area.. protocols.. to store forward.. skus for the forward-pick area.. space by auction.. uneconomical picks.. presentation..908 Layout of a piece-pick-from-carton is a fast-pick area?.. restocks.. much of each sku to store in the fast-pick area?.. labor to maintain a forward pick area.

3 Commonly-used storage strategies.. with optimal.. costs per restock.. and maximum allocations.. points and safety stock.. skus go into the fast-pick area?.. skus to minimize labor.. to equalize space or restocking frequencies.. comments on the model.. issues.. by family.. for safety stock.. on capacity.. for on-hand inventory levels.. costs.. uneconomical picks.. fast-pick areas.. of the fluid model.. of the fast-pick area.. large should the fast-pick area be?.. can the fast-pick area be made larger?.. the lighter side.. Questions.. 1269 Detailed orientation and stack level.. algorithms.. Fit.. Fit.. on packing algorithms.. issues.. 1476 CONTENTSIII Order-picking14910 Routing to reduce The problem of pick-path optimization.

4 Heuristic methods of generating short pick paths.. Path outlines.. Product placement.. Pick-path optimization.. How to take advantage of optimization.. How much is optimization worth?.. Summary.. Questions.. 16711 Work flow and Organizing a team of order-pickers.. A model of work and workers.. Improvements that are not.. Some advantages of bucket brigades.. Bucket brigades in the Warehouse .. Summary.. Questions.. 184IV Automation18712 Carousels, A-frames, and Carousels.. Control.. Storage.. Throughput.. A-frames.. In-aisle cranes, AS/RS, and their relatives.. Throughput.. On the lighter side.. Questions.. 208V Special topics21113 Why crossdock?

5 Operations.. Freight flow.. Congestion.. Design.. Size.. Geometry .. Trailer management .. Resources .. Questions .. 224VI Measuring Warehouse performance22514 Activity Basics.. Warehouse activity profiling.. ABC analysis.. Statistical analysis.. Doing it.. Visualization.. Summary.. On the lighter side.. Questions.. 25015 Performance measurement.. Benchmarking.. Ratio-based benchmarking.. Aggregate benchmarking.. Are smaller warehouses more efficient?.. Questions.. 262 VII Miscellaneous26316 Warehousing around the North America.. East Asia.. India.. China.. Singapore, Hong Kong, Japan.. Central and South America.

6 Europe.. 27317 In preparation275 VIII Appendices281A The Economic Order The Economic Order Quantity.. Safety stock and reorder points.. Implications for the Warehouse .. 288B The Knapsack Problem289C The Shortest Path Problem293 List of andnstores the transportation plan consists ofmndirect shipments, each relatively small and likely subject to the higher,less-than-truckload rates.. are onlym+nshipments through an intermediate aggregator,such as a Distribution center or crossdock. Furthermore, each shipmentis larger and more likely to qualify for the lower, full-truckload failure rate of many mechanical components follows a bathtub Distribution , which means demand for these parts is higher at the be-ginning and at the end of .. two pipes have the same rates of flow, the narrower pipe holds lessfluid.

7 In the same way, faster flow of inventory means less inventory inthe pipeline and so reduced inventory .. product is generally handled in smaller units as it moves down thesupply chain. (Adapted from Warehouse Modernization and Lay-out Planning Guide , Department of the Navy, Naval Supply SystemsCommand, NAVSUP Publication 529, March 1985, p 8 17).. these 25,000 skus there is little correlation between popularityand physical volume of product .. among these 25,000 skus varies enormously, which presentsspecial challenges to effective .. idealization of how the inventory level at a location changes over ofklocations to hold product under a policy of shared step function represents the space devoted to holding shared storage, space utilization increases with additional stor-age locations, but at a diminishing.

8 Is the most labor-intensive activity in most can be reduced by careful .. pallet rack. (Adapted from Warehouse Modernization andLayout Planning Guide , Department of the Navy, Naval Supply Sys-tems Command, NAVSUP Publication 529, March 1985, p 8 17)..40910 LIST OF , or static rack. (Adapted from Warehouse Modernizationand Layout Planning Guide , Department of the Navy, Naval SupplySystems Command, NAVSUP Publication 529, March 1985, p 8 17.) flow rack for cartons. (Adapted from Warehouse Modern-ization and Layout Planning Guide , Department of the Navy, NavalSupply Systems Command, NAVSUP Publication 529, March 1985, p8-17.) .. views of the shelves of three styles of carton flow rack. Eachsuccessive configuration presents the product more conveniently but atthe cost of consuming more space.

9 Configurations (b) and (c) occupymore horizontal space than (a) and configuration (c) also occupies morevertical space.. of unit-loads through a typical Warehouse .. that require extra labor to retrieve.. floor space charged to a lane includes storage space, any gap be-tween lanes, and one-half the aisle width in front of the .. , measured as pallet position-days that are unoccupied but un-available, depends on both the lane depth and the aisle width. Thefour pallets of this sku should be stored either 2-deep or else 4-deep,depending on the width of the .. single-cycle protocol, half of all forklift travel is unproductive(red lines). In this example, both receiving and shipping are at thebottom (black disk). Trips to stow a pallet in an available location (graysquares) require that the forklift return with empty forks.

10 Similarly, anytrip to retrieve a pallet from a location (black squares) requires that thejourney begin with empty .. can reduce dead-heading by enabling travel directly from astow to a retrieval. In this example, each of two stows (gray locations)have been paired with a retrieval (black locations). Dead-heading isshown in .. receiving and shipping are separated, a dual-cycle trip must dead-head between them (dashed red line in the center).. blue location (right) is more convenient than the red location (left)because the total distance from receiving to the location, and from thereto shipping is .. receiving and shipping are located at opposite sides of the ware-house there are many locations of equal convenience, and with the mostconvenient on a line between shipping and receiving.