Warehouse Design Module
Warwick University – MSc Logistics
Agenda
Warehouse Design Module 2
Course Sections
1. Introduction
2. Warehouse Design Overview
3. Data Analysis
4. Warehouse Design Options – Racking
5. Warehouse Design Options – Shelving
6. Warehouse Design – Material Handling
Equipment (MHE)
7. Warehouse Automation
8. Questions
• Qualifications
• MSc Industrial Logistics (Supply Chain
Management)
• Chartered Member of the Institute of
Logistics and Transport CMILT
Overview
• Tony is an experienced supply chain
professional specialising in warehouse and
logistics solution design. Experience
includes, warehouse and operations design,
simulation, labour planning and modelling,
facility design, and logistics network analysis.
Experience of specifying and
implementation of Warehouse Management
Systems.
Key Skills
Warehouse Design & Layout, Warehouse Simulation and Modelling, Warehouse Automation Design and Specification, Stock
Profiling and Storage equipment design, Project Management, Warehouse Management Systems Specification and
Implementation
Key Companies
Rolls-Royce Aerospace, Specsavers, Great Bear, Clipper Logistics, Princes Foods, Mondelez, AS Watson, Reckitt Benkiser,
Polypipe, DHL, Ceva, Yusen, NFT, Delhaize, Superdry, Boots, Virgin Media, Wolseley, Homebase, Sainsburys, GM, Peugeot
Experience
• Warehouse Design | Over 30 years warehouse design experience having worked with most of the major 3rd Party
Logistics providers across the world. Trained user of AutoCAD and has expert knowledge of all types of storage media
and warehouse equipment and operationally astute.
• Warehouse Automation| Design Engineer responsible for various Automation and Integration projects, systems include
ASRS, AGV’s, conveyors, pick to light systems, sorters, goods to man solutions, WCS and WMS.
• Project Management | Consultant role for Virgin Media managing the operational process design and mapping and then
configuration of Red Prairie WMS. The scope included the planning of the stock transition and warehouse design from
multiple remote sites into a National Distribution Centre. Project managed the physical stock transfer, the design and
fit out of the new DC, planned the recruitment programme and the go live of the WMS. This was a 9-month contract –
the new DC was 250,000 sq. ft including racked and shelving areas and designed to comply with stringent security
requirements.
• Resource Modelling | Qualified as an Industrial Engineer and expert user of simulation tools used to develop resource
models to calculate Labour, MHE and Equipment capacity requirements to meet varying activity levels and to model the
effects of seasonality.
• Logistics Network Design | using network modelling and centre of gravity software has developed logistics strategies
using both financial and pragmatic assessment of network options numerous companies.
• B&Q | Redesign of 600,000 sq. ft. part automated warehouse . Including ASRS, Automated Crane Storage System, Zone
to Zone conveyor systems, Voice Picking System and Radio Shuttle Car storage solutions. Design included WCS
specification, pick stations, layout and process evaluation.
1. Introduction Tony Hughes
• Logistics Consultant – Self Employed Contractor
Warehouse Design Module
1. Introduction
Module Objective
• To provide a high level understanding of the basic principles of warehouse design.
• Basic concept of data collection, validation, collation and analysis.
• Definition of the warehouse.
• Evaluation of concepts
• Final Design
Warehouse Design Module 4
2. Warehouse Design Overview
Warehouse Design Module 5
▪ Whilst every project is different and requirements may slightly vary, the approach to develop an optimised process remains
broadly consistent any warehouse design process, and consists of six steps:
▪ Data profiling allows us to understand your data but more importantly, supports sign off to ensure that the data is
complete, without duplicates and representative of the activities to include in the solution design.
▪ Product flows and routes are mapped and clarified in order to inform the modeling. Each physical movement becomes an
element within the simulations. This means we will need observe the operations and discuss the processes and activities
with the team.
▪ Data profiling and baseline models require sign-off before we progress to the design stage.
•Review & re-confirm
objectives
•Establish project
team and governance
•Confirm Data
Requirements
•Agree activity
schedule & support
required
Kick Off
Meeting
•Volumes
•Frequencies
•SKUs
•Customers
•KPIs
•Routes
Data Collection •Understanding
•Evaluation
•Summarising
•Mapping
•Assumptions
•SIGN OFF
Data Profiling
•Processes
•Data Mapping
•Further Questions
•Assumptions
•Baseline model
development
•SIGN OFF
Baseline
Establishment
•Modelling
•Review
•Sensitivity Testing
•Draft output
Options
Development
•Report
•Recommend
•Refine
•Sign-off
Recommendation •Develop Design
•Support Change
Management
•Validate &
Review
Implementation
2. Warehouse Design Overview
Warehouse Design Module 6
Role of the warehouse Storage vs Processing
• More, smaller transactions
• Handle and store more items
• Offer more Value-Added activities
• Process more returns
• In less time with less errors
• With less skilled workforce
• With more WMS capability
2. Warehouse Design Overview
Warehouse Design Module 7
The Solution Design Objective Functions
Typically required due to the following
reasons:
• New Customer
• Change in current operations
• Increased volumes
• Change in order types
• Increased SKU range
• Relocation to a new site
• New service offering
• Ecom
• Click and Collect

3. Warehouse Design Data Analysis
Data Collection
Warehouse data :
• Name of Site / Address
• Drawings if available – AutoCAD preferred
• Site operating times
• Site security / traffic routes / parking areas
Warehouse Design Module 8
Item master file
• SKU Code
• SKU description
• SKU Category / product group
• SKU dims – units / case / pallet
• Quantity per case / pallet
• Weight per case / pallet
• Ti Hi information – quantity per level, number of
levels per pallet
3. Warehouse Design Data Analysis
Data Collection
Inventory reports – one off
report (Snapshot) – 12 months
• By location :
• SKU
• Quantity of units – in single units /
cases
Locations report
• A full listing extracted from the WMS
to identify all locations in the
warehouse
• By type – e.g. shelf, pallet, etc
• By zone
Warehouse Design Module 9
3. Warehouse Design Data Analysis
Data Collection
Warehouse Design Module 10
Order data (12 months data preferred)
• Customer name / code
• Order number
• Order type (Next day – 2 day – stock order, etc)
• SKU
• Quantity
• Typical order analysis – by order type
• Number of Single SKU orders
3. Warehouse Design Data Analysis
Data Collection
0
10
20
30
40
50
60
70
80
90
100
Receiving report (12 months data) Inbound Vehicle Analysis
• Date / Time
• Number of vehicles
• Load sizes
• Items on each vehicle
Despatch report (12 months data)
• Same details as above but showing load type
• Parcels / Full pallet loads / Stock Orders, etc…
Warehouse Design Module
Personnel
• Number of employees per shift, buy function to
include management / supervision
KPI list
• List by function of the standard task rate
MHE listing
• Full list of all MHE by type
WMS
• Functionality checklist
3. Warehouse Design Data Analysis
• Data Collection
FTE Breakdown by Function AM Shift PM Shift Night Shift
Function
Receiving 17 20 4
Quality 12 14 7
Replenishment 25 30 4
Admin 7 8 4
Bulk Replen 8 9 4
Inventory 6 6 6
Value Add 4 4 2
Order Release 6 7 3
Loading totes onto conveyor 2 2 1
Despatch UK + EU 40 48 24
Despatch Intl 20 24 12
Packing 40 48 24
Non Productive 20 24 12
Picking 80 120 50
287 364 157
Warehouse Design Module
Site Visit
• Verify the layout – check the racks / shelfs is consistent
• Establish what tasks are performed where – understand
the flows
• Confirm what tasks are performed at what times
• Confirm service levels by order type i.e. 6pm cut off for
next day deliveries – pick completion by time
• Verify data – challenge gaps
3. Warehouse Design Data Analysis
• Data Collection
Warehouse Design Module
So what data do we need as a basis for
design?
• Regarding the product, we need good quality data
about:
• Product Characteristics
• Product Sizes
• Stock Levels
• Throughput
• Order Patterns
• Special Requirements
Product Data – Full List of the items
to be stored:
• Characteristics – flammable, chilled, fragile,
valuable…
• Case sizes (L x W x H)
• Part numbers & descriptions
• Item weights / pallet load weights
• Pallet load size (L x W x H) – see next slide
• Items / cases / sacks / totes per unit load
3. Warehouse Design Data Analysis
• Data Collection
Warehouse Design Module
• Cartons, boxes, sacks, bags
• Pallets, cages, stillages, roll cages
• Tote bins, trays
• IBCs, tanks, bag in box, large bags
3. Warehouse Design Data Analysis
Handling units
Warehouse Design Module
Stock Holding Analysis we need stockholding levels, in
total and by individual product line (SKU), i.e. :
• Maximum stock
• Minimum stock
• Average stock
Taking account also of:
• Seasonality (over 12 months)
• Forward Projections (future years)
2. Warehouse Design Data Analysis
• Data Collection
Warehouse Design Module
The basic throughput data required are:
• Pallets / cases / items / units per day or week
• Maximum, minimum and average quantities
• Seasonality
• FIFO?
• Shelf Life?
• Special handling?
• Don’t forget product returns (often a big feature for some
operations in B2C)
3. Warehouse Design Data Analysis
• Data Collection
Warehouse Design Module
Order Patterns
• Service level – delivery time, product availability
• Lead times and ‘cut offs’
• Orders per shift per day or per week
• Lines per order (averages and ranges)
• Cases or items per line
• Maximum, minimum and average activity levels
• Seasonality demands
3. Warehouse Design Data Analysis
• Data Collection
Warehouse Design Module
ABC – Pareto Analysis
3. Warehouse Design Data Analysis
• Data Analysis – ABC Pareto Analysis – The 80-20 Rule: “The Law of the Vital Few & The Trivial Many”
Logic
• The pareto 80:20 rule is based on the
logic that for many events, roughly
80% of the effects come from 20% of
the causes. In the case of a
warehouse this logic is applied
typically to picking analysis. In the
example above 20% of the SKU’s
accounts for 80% of the pick lines –
these are classified as the “A” items.
Warehouse Design Module
Projections
What are we designing our warehouse to do?
When looking forward the scenarios might be:
• Growth, stability or even retrenchment
• Greater or lesser stockholdings
3. Warehouse Design Data Analysis
• Data Future Growth
• Wider or reduced product ranges
• The introduction of completely new product ranges
• Different combinations of these variables
• Additional services (value added)
Warehouse Design Module
If we are using an existing building, then we need full
details of:
• Floor strength and flatness
• The clear working height (not just the eaves height!)
• An accurate scale drawing showing:
– obstructions / emergency exits
– dock levelers and doors, etc.
– drains and manhole covers
– lighting runs – sprinkler locations / water tanks
– fire fighting equipment (hoses and sprinkler installations)
• Most important: check for cracks in the floor and leaks in the roof!
3. Warehouse Design Data Analysis
• Existing Building – Possibly supported with a site survey
Warehouse Design Module
For green field or brown field sites, we need:
• Plans of the site and the surrounding area
• Confirmation of accessibility to site (24/7?)
• Available services (power, gas, water, Communications, 4 /
5g)
And, before we make any commitment:
• An independent ground survey, checking for load bearing
capacity, drainage / history of flooding and soil
contamination
• Existing planning permissions or, if not available, existing
similar facilities close by (and operating without
restrictions)
3. Warehouse Design Data Analysis
• New Build Warehouse
Warehouse Design Module
3. Data Analysis-Day in the Life Of Mapping
23
Day in the Life Of
The day in the Life of diagram
provides another way of reporting
activity within an operation. This
tool can also identify potential
bottlenecks as they occur during the
working hours of a day or throughout
a week.
Day 2
08:00 09:00 10:00 11:00 12:00 13:00 14:00 15:00 16:00 17:00 18:00 19:00 20:00 21:00 22:00 23:00 00:00 01:00 02:00 03:00 04:00 05:00 06:00 07:00 08:00 09:00 10:00 11:00 12:00
Area 09:00 10:00 11:00 12:00 13:00 14:00 15:00 16:00 17:00 18:00 19:00 20:00 21:00 22:00 23:00 00:00 01:00 02:00 03:00 04:00 05:00 06:00 07:00 08:00 09:00 10:00 11:00 12:00 13:00
Orders Recived in WMS FP 1 GR3 NSI
Picking Shift AM Picking shift – 04:00 to 11:00
AM Picking shift – 04:00 to 11:00
PM Picking shift – 11:00 to 18:00 No Labour Night Picking shift NSI – 21:00 to 04:00
Night Picking shift Stock – 22:00 to 05:00
Pick Window Wave 1 Pick window 10% am pick – 90 % pm pick
FP 1 Loading Wave 1
FP 4
Wave 2 Pick 20 % pm pick No Labour FP4 80% pick on nights
Loading Wave 2
FP 4 No pick pm No Labour Wave Pick 100 % nights pick FP4
NSI Wave Pick 100 % nights NSI
Loading Wave 3
FP 4 Wave Pick 100% am pick FP4
GR3 Wave Pick 100% am pick GR3
NSI Wave Pick 100% am pick NSI
Loading Wave 4
Units Loaded 20088 units wave 4
Day in the Life – Future Scenario
23862 units wave 1 9086 units 32936 units wave 3
Warehouse Design Module
• Outputs from Analysis
3. Data Analysis – Material Flow Diagram
24
Flow Diagram
Material Flow
Diagrams are
generated to provide
a visualisation of the
key tasks performed
through an operation
The diagrams can
identify potential
bottlenecks in
operations
Warehouse Design Module
• Outputs from Analysis
1. Adjustable Pallet Racking
2. Block Stacks
3. Drive in racks
4. Narrow Aisle racks
5. Double Deep racks
6. Push Back Racks
7. Live Racks – inclined – gravity racks
8. Shuttle racks – equipped with a cart
9. Mobile racks
4. Warehouse Design Options – Racking
Racking Types
Warehouse Design Module
4. Warehouse Design Options – Racking
1. Adjustable Pallet Racking
26
Adjustable Pallet Racking
• Typically operated using Reach trucks for
reserve locations
• Each individual pallet is accessible
• Picking done at low lever using Low Level
order Pickers – LLOP’s, or and pallet trucks –
manual or powered. Picking trolleys.
• Racks can be fitted with beams to provide a
shelving pick solution
Warehouse Design Module
4. Warehouse Design Options–Racking
27
Example Block Stack Warehouse
Block Stacking
• Typically used for items difficult to store in racks.
Maybe due to the pallet types, or the overhang
of product, the weight of the pallets, etc
• Or used for Cross docking of fast items , the
stock turns quickly – usually located by dock
turns.
• White Goods – Clamp Trucks
2. Block Stacks
Warehouse Design Module
4. Warehouse Design Options – Racking
3. Drive In Racks
28
Drive In Racks
• Fork lift trucks and Reach trucks
• Typically used dense storage of same products in each
lane.
• Access to pallets limited
• Limited applications
• Rack prone to damage
Example Drive In Racks
Warehouse Design Module
4. Warehouse Design Options – Racking
4. Narrow Aisle racks (VNA)
29
Very Narrow Aisles
• Aisle width of between 1.6m and 2.0m depending on height
/ weight of pallets
• Operated in by either Articulated Fork Lift Trucks, turret

Man Down – Turret Truck
Warehouse Design Module
4. Warehouse Design Options–Racking
30
Double Deep racks
• Pallets stored 2 deep in racks
• Accessed using reach trucks or articulated trucks
• Trucks fitted with a telescopic attachment to
allow for access to 2nd location
• Attachment reduces lift height of truck
• Only suitable for a limited range of storage types
• Same SKU / batch
• Cannot mix SKU / batch in a location
• WMS needs to support put away logic
5. Double Deep racks
Example Double Deep Racks
Warehouse Design Module
3. Warehouse Design Options–Racking
31
Push Back Racks
• Push-back racking for pallets has a single loading
and unloading area
• Push-back with shuttles: In the system with
shuttles, each pallet, except the last one, is
deposited on a shuttle, which moves on rails
with a slight incline.
• Push-back with rollers: The pallets are moved by
means of roller beds fixed to the structure with a
slight incline.
6. Push Back Racks Example Push Back Racks
Warehouse Design Module
4. Warehouse Design Options–Racking
32
Pallet Flow Racking, or “Pallet Live
Storage”
• Operated using Reach trucks / Forklift trucks
• Inclined – 4 % typical
• Braking mechanism stops pallets at the lowest
point
• Pallets need to be good condition
• Can be used in despatch for marshalling
Gravity – Live Racks
7. Live Racks
Warehouse Design Module
4. Warehouse Design Options – Racking
8. Shuttle racks – Operated using a cart
Warehouse Design Module 33
Shuttle Racks
• High-density compact storage solution
• Reach trucks / Fork lift trucks
• Deep Channels in racks – shuttle moves pallets into
position
• Shuttles are remotely controlled by an operator
• Pallets need to be good condition
> Combined Storage and Picking
Solution
> Reserve locations (2, 3 4 and 5th
level) use Shuttles in racks
> Pick locations supplied from rear
on gravity racks
> This is a good example of mixing
concepts

Radio shuttle Racking – End Elevation
4. Warehouse Design Options – Racking
• 8. Shuttle racks – plus flow racks
Replenishment Replenishment
Warehouse Design Module
4. Warehouse Design Options – Racking
9. Mobile Racks
Warehouse Design Module 35
Mobile Racks
• Reach trucks Remotely
controlled by driver –
or by WMS if the
system is sophisticated
• Racks run on rails
recessed in the floor
• Not suitable for fast
moving operation
• Design considerations – table
Adjustable Pallet Racking
Block Stacks
Drive in racks
Narrow Aisle racks
Double Deep racks
Push Back Racks
Live Racks
Shuttle racks with carts
Mobile racks
Utilisation of floor area 2 2 4 4 4 3 3 5 5
Utilisation of building height 4 1 4 5 4 4 4 4 4
Usable cubic storage space 3 1 5 5 3 3 4 5 4
Speed of access & throughput 4 2 3 2 3 3 3 2 2
Access to individual pallets 5 2 2 5 2 2 2 2 3
Stock rotation 5 2 3 5 3 2 4 2 4
Specialised handling equipment No No No Yes Yes No No No No
Ease & speed of installation 4 5 3 2 3 3 3 3 2
Ease of re-location 3 5 2 1 2 2 2 2 1
Adjustment of pallet positions Yes N/A Yes Yes Yes Yes Yes Yes Yes
Maximum height in metres 13 5 12 16 13 13 13 13 13
Cost per pallet £30 £1 £80 £35 £35 £200 £200 £80 £250
Scores out of 5
4. Warehouse Design Options – Racking
Comparison Table
Warehouse Design Module
Warehouse Design Module 37
Adjustable Pallet Racking (APR)
100
91 111
118
3
Number of Pallets 8,000
11
Utilisation 85% 361
101
Bays per run 13 4
Total Storage pallets 9,412
Bays 286
Double runs 11.0 166
Stoage area 29,291 sq.ft
Total Height 17,170 mm
Top Beam 15,900 mm
Beam Loading 3,000 KG Key
Frame Loading 33,000 KG xx
Pallet to upright cleance OK
Pallet over hang Front & Back OK
= input cell
Data selection
Select for Yes
Fork Entry
Aisle
Frame to Frame
MHE Type
Frame
Depth
Sprinklers
Main Menu
• Tool developed to quickly compare alternative
storage concepts
• Various Rack Designs and MHE operating
specifications can be evaluated
4. Warehouse Design Options – Racking
Warehouse Sizing Tool Design for 18,200 pallets
1. Long span / Short span shelving
2. Mezzanine Shelving
3. Mobile in Rack Shelving
4. Live shelving
5. Mobile Shelves
6. Mezzanine Floors
5. Warehouse Design Options –Shelving
Shelving Types
Warehouse Design Module
• Long span / Short span shelving
• Shelving can be located in racks as shown on the right – or free standing
as on the left
• Provides dense storage of smaller items
5. Warehouse Design Options –Shelving
1. Long span / Short span shelving
In Rack Shelving
Free Standing Shelving
Warehouse Design Module
• Long span shelving can be used to support
mezzanine structure
• Provides good use of vertical space
• Ideally fast moving items located to the
lower level
5. Warehouse Design Options –Shelving
2. Mezzanine Shelving
Warehouse Design Module
• Relatively new concept
• Provides dense storage in pick face
• Racks are on rails – easily moved so
operators can access varying
depths
• Fast moving items positioned to
front – slow movers to rear
5. Warehouse Design Options –Shelving
3. Mobile in Rack Shelving
Warehouse Design Module
> Gravity feed of items to the pick face
> Replenish from rear – pick from front
> Enables separation of MHE from pick aisles
5. Warehouse Design Options –Shelving
4. Live Shelving
Warehouse Design Module
• Aisles accessed by using levers to open
aisles
• Ideal for dense archive storage of files and
records
5. Warehouse Design Options –Shelving
5. Mobile Shelving
Warehouse Design Module
• Uses height of building – space is “free of
charge”
• Sometimes placed above goods receiving /
despatch
• Multiple layers can be used
• Accessed via lifts / conveyors / pallet gates
5. Warehouse Design Options –Shelving
6. Mezzanine Floors
Warehouse Design Module
1. Fork Lift Truck
2. Reach Truck
3. Articulated Truck
4. Powered Pallet truck
5. Order Picking Trucks
6. VNA Trucks
7. Manual Picking Trolleys
6. Warehouse Design – Material Handling Equipment (MHE)
MHE Types
Warehouse Design Module
• Typically used for
• Unloading / Loading vehicles
• Yard duties
• Sometimes to store pallets in racks – drive in or APR
• Can be fitted with a variety of attachments
• Double pallet handling accessories
1. Fork Lift Trucks
6. Warehouse Design – Material Handling Equipment (MHE)
Warehouse Design Module
Slip Sheet Attachment
Roll Attachment
Hydraulic Clamp Attachment
1. Fork Lift Truck Attachments
6. Warehouse Design – Material Handling Equipment (MHE)
Warehouse Design Module
• Typically used for moving received
items into racks / P&D locations
• Also used to replenish pick faces
in wide aisle picking areas
• A reach truck can operate in aisles
of 2.8 metres or more if the truck
is larger
• Used to am maximum height of 13
/14 metres
• The higher the lift height the
larger the truck – the wider the
aisle required.
2. Reach Trucks
6. Warehouse Design – Material Handling Equipment (MHE)
Warehouse Design Module
• Multi function truck
• Unloading / loading
• Put Away / Retrieval
• Operate in narrow aisles – less than 2 metres
• Can operate up to approx. 11 metres lift
• Can be used with attachment to store
double deep – restricts height
3. Articulated Fork lift trucks
6. Warehouse Design – Material Handling Equipment (MHE)
Warehouse Design Module
• Typically used for unloading and loading
operations
• Manual walk behind trucks also available
• Also used for general warehouse transfers
• Can be fitted with extended forks to carry more
than 1 pallet or cage at a time
4. Ride On PPT’s powered pallet trucks
6. Warehouse Design – Material Handling Equipment (MHE)
Warehouse Design Module
• Man Up and Man Down trucks available
• Trucks fitted with forks to enable operator to pick directly onto
pallet, or trays or cartons.
• Allows for complete order pick of slow and fast moving items
• Allows for higher locations items to be picked separately and
consolidated at a later stage as an alternative
5. Order Picking Trucks
6. Warehouse Design – Material Handling Equipment (MHE)
Warehouse Design Module
• Used in aisles of between 1.6 and 2.0 metres up to heights of 16m

• Trucks can also be used for picking tasks
6. Very Narrow Aisle Trucks
6. Warehouse Design – Material Handling Equipment (MHE)
Warehouse Design Module
• Operator pushes trolley around warehouse – can be used with pick to
light system
• Can be designed with steps to allow for accessing higher locations
7. Picking Trolley
6. Warehouse Design – Material Handling Equipment (MHE)
Warehouse Design Module
Warehouse
Automation
Warehouse Design Module 54
7. Warehouse Design -Automation
1. Vertical Carousel
• Uses height of building
• Very dense storage
• Can provide secure storage of valuable items
• Can be slow to access items –
• Vertical Carousel has carriers fitted to a chain drive –
the carriers are rotated in both directions.
• ABC analysis and stock profiling and accurate location
of fast moving items can lead to pick efficiencies
Warehouse Design Module 55
2. Vertical Lift Module
• Similar concept to Carousels
• VLM’s can handle heavier loads and can
be designed up to 30m high
• Both VLMs and Carousels can be fitted
with laser guide and pick to light
technology
• VLM’s can have different height trays –
Carousels carriers are the same size
Warehouse Design Module 56
7. Warehouse Design -Automation
3. ASRS Mother And Child Shuttle System
• Automated Storage and
Retrieval system
• Design includes induct, lifts,
mother and child shuttles
• Allows for multiple SKU’s to
be stored in 1 lane
• Provides very dense storage
solution
Warehouse Design Module 57
7. Warehouse Design -Automation
3. ASRS Mother And Child Shuttle System
• Automated Storage and
Retrieval system
Warehouse Design Module 58
7. Warehouse Design -Automation
3. ASRS Mother And Child Shuttle System
• Automated Storage and
Retrieval system
Warehouse Design Module 59
7. Warehouse Design -Automation
3. ASRS Automated mini load
• Provides dense high level storage
• Allows for Totes or trays to be
sequenced to pick operators
• May be used in conjunction with
another smaller mini load to supply A
Classification items
Warehouse Design Module 60
7. Warehouse Design -Automation
4. Picking Solutions – Collaborative Robots
• Collaborative Robots
• Robots move between “Zones”
• Robots directed to a pick location
• Robots interact with the warehouse staff
• By using bulti in screens can give
instructions and confirm picks
• Screen can be configured for different
languages
• Screen can provide visual help
• Main benefit is reduced walk – non value
adding tasks reduced significantly
Warehouse Design Module 61
7. Warehouse Design -Automation 6 Rivers Systems
4. Storage and Picking Solutions –HIK Goods to Man Robots
Tasks allocated
• Picks
• Replenishment
• Putaway
• Returns
• Cycle Counts
Warehouse Design Module 62
HIK Robots – Fetch
7. Warehouse Design -Automation
Pick to Light – Picking Systems
• Gravity feed of items to the pick face
• In this case shown using pick to light
• Operator inducts a tote or tray to the
pick zone
• The system knows what order is
assigned to the tote and displays the
pick quantities on the pick to light panel.
• The operators confirm the pick quantity
using touch pad.
• When the pick is complete for the zone
the all of lights flash.
Warehouse Design Module 63
7. Warehouse Design -Automation
Put to Light – Picking Systems
• Can be used as part of a Put Wall Process
• Positions in shelves are allocated to a
customer order
• Operator scans item and the wall
illuminates to show destination position.
• In the case of a wall, on the reverse side
of the wall can be a pack station, and
when an order has been completely
picked then the put wall will indicate this
to the packer, who in turn retrieves the
picked items, presses a confirmation
button and packs the order.
• At this point the position is now vacant
and the system will allocate the next
order to the position.
Warehouse Design Module 64
7. Warehouse Design -Automation
Packing Systems Auto Bagging / Packing
• Machine capable of 2,000 parcels an
hour
• Includes addition of invoice inside the
bag and labelling of bag with shipping
details and carrier
• Ideally linked to a sorter – which will
provide a secondary scan – allows for
sortation by carrier by route, and also
allows for miss read labels to be
reprinted.
• Similar concept is available for auto
carton assembly – reduced rates – same
logic applies for sortation and carton
labelling.
Warehouse Design Module 65
7. Warehouse Design -Automation
Voice Recognition – Picking Systems
• Operator receives instructions via the
headset and confirm tasks such as picks
using predetermined commands
• Voice allows for hands free paperless
operations
• The voice commands can be language
specific for the user
• The user can train the software to learn
the operators way of saying certain
words, specific to that user
Warehouse Design Module 66
7. Warehouse Design -Automation
6. Storage and Picking Solution – Autostore
Warehouse Design Module 67
7. Warehouse Design -Automation
6. Storage and Picking Solution – Autostore
• Plastic trays stored in stacks
• Robots lift trays from the stacks from above
• The robots travel along grid rails
• The robots can lift 1 tray at a time and by means of
digging can access lower trays
• The robots work as a team, so to access the 4th bin
in a stack 4 robots may be involved in the process
• Fast moving trays naturally work their way to the
top of stacks
• New receipts are added to trays at an induct port
• For picking trays are delivered to ports where
operators perform picking tasks
• Common for other technologies such as pick to
light to be used
Warehouse Design Module 68
7. Warehouse Design -Automation
6. Storage and Picking Solution – Autostore
Advantages
• The system can be extended easily with the addition
of extra stacks and ports
• The system can be used as part of an extension to a
warehouse
• Autostore does not need to have special floor
surfaces.
Disadvantages
• 4-year payback and require a high capital investment
Warehouse Design Module 69
7. Warehouse Design -Automation
8. Storage and Picking Solution – Conveyors and Cranes
• Allows for automated for manual operation
• Can operate in excess of 40 metres in height
• Can operate double deep
• Provides dense storage in high bay warehouse
• Lights out warehousing – no operators required
• Pallets can be retrieved to a pick station and returned
into the storage area if required
Warehouse Design Module 70
7. Warehouse Design -Automation
9. Automated Guided Vehicles – AGV’s
• Allows for automated for movement of items from
one location to another
• Typically used for repetitive moves from and to fixed
locations
• natural navigation they can scan buildings and using
fixed point maps
• Fast go live
• Routes can be easily modified
• Additional AGV’s added at a later date if volumes
increase
• AGV’s can work 24 / 7 – payback can be less than 1
year
Warehouse Design Module 71
7. Warehouse Design -Automation
9. Automated Sorters Cross Belt Sorter
• Sorters can be used for
sorting packed orders by
carrier / destination
• Pack orders can be delivered
to shipping containers
• Additional scanning can be
used to pre advise carriers
of expected collections
• Sorters can also be used to
enable sorting of batch /
bulk picked orders – and
sorted by customer.
• Very efficient picking
method
Warehouse Design Module 72
7. Warehouse Design -Automation
10. Booms and Conveyors
Telescopic Boom Conveyor
• Used for loading / unloading loose items
• Ideal for De-stuffing containers
• Reduces operator fatigue
• Reduces time on docks
• Allows for sorting of products after
unloading
• Often used in conjunction with conveyor
systems – Bar code readers can direct items
around a conveyor
• Reduces movement
Warehouse Design Module 73
Can also be
used in
place of
dock leveller
or platform
7. Warehouse Design -Automation
11. Storage and Picking Solution – Conveyors and Mezzanine Floor
• Mezzanine Floors and Conveyorised Pick Zones
• A conveyor system can be used to route cartons /
trays to specific zones.
• Can be used for put away and picking.
• These can be used with a combination of Pick to light
or shelving systems
Warehouse Design Module 74
7. Warehouse Design -Automation
Final Design -Conclusions
• Consider all of the options
• Shortlist them – consider advantages / disadvantages of each
• Produce schematic layouts
• Produce resource models or if possible simulate the operation
• Produce cost models
• Consider the Return in investment for longer term high
capital investments
• Compare more than 1 option
Thank You
Tony Hughes
+44 7960 213193
[email protected]
Tony Hughes Consulting Ltd
76
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www.thlogisticsconsultant.com
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Questions ?
Please ask any questions you may have.
Warehouse Design Module 77
7. Resource Modelling
Warehouse Design Module 78
Resource Models
• A key tool in the warehouse
design process is the resource
model. This model will
generate labour and MHE
requirements over a period.
• Once the model has been
created it can quickly be
modified to allow for volume
fluctuations, or to change the
work over different
operational hours.
Activity FTE Man day
Minutes Total %
Inbound Factory 3.02 450 1.12 37% 1.12 37% 0.79 26% 100% 1.12 1.2 100% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0%
Inbound Other 0.06 450 0.03 50% 0.03 50% 0.0 0% 100% 0.03 0.1 100% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0%
Inbound (Handball) 0.33 450 0.33 100% 0.0 0% 0.0 0% 100% 0.33 0.4 100% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0%
Tram Pallet to VNA 0.66 450 0.23 35% 0.26 40% 0.2 25% 100% 0.00 0 0% 0.26 1 100% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0%
Put Away Full Pallet VNA 1.11 450 0.39 35% 0.45 40% 0.3 25% 100% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.45 1 100%
Put Away Full Pallet Wide 4.19 450 1.47 35% 1.68 40% 1.0 25% 100% 0.00 0 0% 1.68 2 100% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0%
Putaway Mixed Case Plt 0.00 450 0.0 50% 0.0 50% 0.0 0% 100% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0%
Replenishment Full Pallet 0.31 450 0.16 50% 0.16 50% 0.0 0% 100% 0.00 0 0% 0.16 1 100% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0%
Replenishment Cases 0.00 450 0.0 50% 0.0 50% 0.0 0% 100% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0%
Full Pallet Pick VNA 0.81 450 0.29 36% 0.52 64% 0.0 0% 100% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.52 1 100%
Full Pallet Pick Wide 3.23 450 1.16 36% 2.07 64% 0.0 0% 100% 0.00 0 0% 2.07 1 100% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0%
Tram Pallet from VNA 0.48 450 0.17 36% 0.31 64% 0.0 0% 100% 0.00 0 0% 0.31 1 100% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0%
Case Pick 1.86 450 0.67 36% 1.19 64% 0.0 0% 100% 0.00 0 0% 0.00 0 0% 1.19 3 100% 0.00 0 0% 0.00 0 0% 0.00 0 0%
Item Pick 0.00 450 0.0 50% 0.0 50% 0.0 0% 100% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0%
Consolidation 0.00 450 0.0 50% 0.0 50% 0.0 0% 100% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0%
Cycle Count 1.38 450 0.7 50% 0.7 50% 0.0 0% 100% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0%
Packing 0.00 450 0.0 50% 0.0 50% 0.0 0% 100% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0%
Marshalling 1.59 450 0.80 50% 0.80 50% 0.0 0% 100% 0.80 1.2 100% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0%
Loading 2.11 450 0.42 20% 1.69 80% 0.0 0% 100% 1.69 2.1 100% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0% 0.00 0 0%
Core Sub Total 21.15 7.9 10.9 2.3 3.96 5 4.47 6 1.19 2 0.00 0 0.00 0 0.96 2
Shift A Shift B Shift C Counterbalance Flexi LLOP Electric Hand Pallet Picking Trolley VNA
8. AutoCAD Design Capability
AutoCAD Warehouse Design
• The process starts with the creation of a site drawing (following
survey), or if available with an existing AutoCAD drawing (verified
for accuracy).
• Various layout concepts can be created.
• The pick and reserve areas can be designed, various options can be
evaluated.
Example Layout
Following SKU and order profile
analysis, and stock holding analysis –
warehouse design concepts can be
evaluated. The most suitable options
can be created in AutoCAD for
reviewing with clients. Various rack
types and associated MHE can be
discussed. Storage and picking
concepts can be discussed – as can
the appropriate use of automation.
Drawings can be issued to rack
suppliers for pricing before site
surveys.
Warehouse Design Module 79
Return On Investment Analysis
8. Financial Payback
• A Financial model used
• Comparison of costs of options requiring capital
investment
• Typically used to demonstrate the payback period of
investment in terms of efficiency gains of one option
to another
Warehouse Design Module 80
4. Warehouse Design Options – Racking
8. Shuttle racks – Operated using a cart
Warehouse Design Module 81
Shuttle Racks
• High-density compact storage
solution
• Reach trucks / Fork lift trucks
• Deep Channels in racks –
shuttle moves pallets into
position
• Shuttles are remotely
controlled by an operator
• Pallets need to be good
condition
4. Picking Solutions – Collaborative Swarm Bots
• Swarmbots
• Same concept as Chuck – order to Man
• More bots, smaller – more agile light load
capacity
Warehouse Design Module 82
7. Warehouse Design -Automation Locus Robotics – Swarmbots
• Used in aisles of between 1.6
and 2.0 metres up to heights
of 16m
• Typically used for moving
received items into and out
of racks by utilising a P&D
location
• Trucks can also be used for
picking tasks
6. Very Narrow Aisle Trucks
6. Warehouse Design – Material Handling Equipment (MHE)
4. Warehouse Design Options – Racking
9. Mobile Racks
Warehouse Design Module 84
3. ASRS – Pallet Storage
• Automated Storage and Retrieval system
• Pallet inducted into system – usually bar coded and
scanned automatically at various stages
• Pallet stored based upon rules
• Serios of sensors scans load to ensure the load is safe
and secure and no overhang of goods on pallets
Warehouse Design Module 85
7. Warehouse Design -Automation