Storage and Warehousing Techniques
WMG Full-time Master’s
Programme
Warehouse Automation and Equipment
Warehouse automation and technology
| Support systems | Semi-automation | Automated systems |
| Warehouse Management systems |
Carousels/Vertical lift modules |
AS/RS (Automated storage and retrieval systems) |
| Warehouse Control Systems |
A frames | Cranes |
| Shuttle systems | ||
| Bar codes and scanners | Pick and put to light | Conveyors |
| Radio frequency ID | Shuttle carts | Automated guided vehicles |
| Vision systems | Robotics |
Warehouse automation
Case study – Tele Danmark site
Introduction of very narrow aisle mini-load crane system.
Consolidated stock from 3 distribution centres and 60 small local sites into a
Single warehouse of 7,200 square metres. This handling system supported
13,500 lines and an annual throughput of 7,000,000 items.
Other benefits included:-
•Handling costs reduced by 75%
•Order accuracy improved from 62% to 96%
•Duplicate stock was almost eliminated
•Flexibility improved – same day order despatches
•Reduced labour costs
Warehouse of the month – Modern Materials Handling Online
Advantages of Automated systems
Increased Space Utilisation
– High bay narrow aisle systems (up to 30 metres high)
– Random storage
Improved Control
– Pallet tracking through enhanced warehouse management system
Labour and Energy Savings
– No heat and light requirement apart from maintenance
– Minimum supervision required
Continuity
– 24 hour, 7 days per week operation
Product Security
– High bay areas, Use of First in First out principles, less human
intervention
Safety
– Elimination of majority of manual handling
– Reduction in accidents
– Can cope with hazardous/harsh environments
Integration
– Coordination of product flows, avoiding bottle necks
– Constant performance levels
– Continuous review
Disadvantages of Automated systems
High investment costs
– Building, equipment, Information technology
System failure, operations are entirely reliant on
technology
High Opportunity cost
Require standardised unit loads
– Anomalies not accepted and need to be handled
separately
More quality control required at inbound
High cost of disposal of equipment
Lack of flexibility
A Frame – automatic pick
Courtesy of Knapp and SSI Schaeffer
A Frame – automatic pick
Other automation systems
Cimcorp 3D shuttle
No racks
Cimcorp video
Swisslog Autostore
Swisslog Autostore Video
Swisslog Autostore
Robotic goods to person
Kiva system – 10,000 sq. metres – $4 – $6 million
Robotic goods to person
Automation in pallet storage
Automation in pallet storage Video
Automated guided vehicle
Automated guided vehicle (AGV) Video
Mechanical (Materials) Handling Equipment – MHE
Choice of pallet movers
Functions to be performed
Type of product
Degree of use – shift length, work patterns, pallets per shift, seasonality,
peaks and troughs, special handling requirements
Travel distances and lift height, inside and/or outside the warehouse,
private/public roads, working conditions (freezer, chill, ambient, hazardous).
Type of fuel, diesel, LPG, Electric. Available ventilation, noise level, space for
re-charging and storing batteries
Store layout and dimensions
Building restraints
Floor condition
Aisle gangway space at front and between racks – can the truck turn 90
degrees. Also needs additional 200mm to its normal turning circle
Delivery and collection vehicles
Access doors, bays, overhead pipes (sprinklers)
Rack heights
Method of acquisition and maintenance
Budget
A variety of trucks to choose from
Courtesy of Toyota
Vertical movement
(Courtesy of Atlet, Toyota, Central Training and Flexi),
22
Vertical movement Video
(Courtesy of Atlet, Toyota, Central Training and Flexi),
23
Horizontal movement
Courtesy of Demag, AS Conveyor Systems and Seegrid),
Pallet movers – Comparison Matrix
| Product type | Lift height | Aisle width (mm) |
Lift capacity in kg from |
To | Cost from (£) | To (£) |
| Hand pallet, truck, pallet jack |
N/A | 1,800 | 1000 | 3,000 | 250 | 1,000 |
| Powered pallet truck | N/A | 2,400 | 500 | 3,000 | 2,000 | 10,000 |
| Powered pallet stacker | 1,350–6,300 mm | 2,400–3,000 | 1,000 | 2,000 | 5,000 | 15,000 |
| Reach truck | 3,000–12,500 mm | 2,650–3,150 | 1,000 | 2,500 | 15,000 | 35,000 |
| Counter-balance truck | 3,000–7,200 mm | 3,000–6,000 | 1,300 | 5,000 | 12,000 | 40,000 |
| Low-level order picker | N/A | 1,600 | 1,600 | 2,500 | 6,000 | 12,000 |
| Medium-level order picker |
2,000–4,700 mm | 1,600 | 1,000 | 1,200 | 10,000 | 24,000 |
| High-level order picker | 4,700–9,500 mm | 1,600 | 1,000 | 1,200 | 20,000 | 36,000 |
| Combination truck | 3,000 – 16,000 mm |
1,600–2,300 | 1,000 | 1,500 | 40,000 | 80,000 |
| Articulated forklift truck | Up to 12,500 mm | 1,600–2,200 | 1,000 | 2,000 | 29,000 | 40,000 |
| NOTE: Prices at May 2017 UK only. Courtesy of Locators Ltd |
Lifetime Costs of MHE Equipment
The pie chart shows the breakdown of
the cost of ownership. Courtesy of
Toyota – 2020
Setting the scene…
Warehouse Storage Justification
Looking for a new
warehouse with 2500
pallet locations…
Warehouse Storage Justification
| CONVENTIONAL SYSTEM | NARROW AISLE SYSTEM | VERY NARROW AISLE SYSTEM |
| Gas, LPG or Electric Trucks | Electric Reach Trucks | Electric Very Narrow Aisle Trucks |
| Clear aisle 4200mm | Clear aisle 2700mm | Clear aisle 1650mm |
| Top beam 4775mm | Top beam 4775mm | Top beam 4775mm |
| Stack 4 high (1 on the ground; 3 in the air) |
Stack 4 high (1 on the ground; 3 in the air) |
Stack 4 high (1 on the ground; 3 in the air) |
| Single command system | Dual command system | Dual command system |
| The truck loads & unloads trailers, loads & unloads rack plus pick up & deliver to manufacturing |
The truck pick up & deposits loads from staging and pick & deposits loads in the rack systems |
The truck pick up & deposits loads from staging and pick & deposits loads in the rack systems |
| 80% Travel. 20% Lift | 60% Travel. 40% Lift | 50% Travel. 50% Lift† |
| 66% Aisle | 51% Aisle | 39% Aisle |
† Travel & LiŌ are simultaneous
| 2554 sq. metres | 1950 sq. metres | 604 sq. metres |
Special equipment – Slip sheet attachment
Slip Sheet Video
Courtesy of easy rack
Courtesy of Bridgestone
Courtesy of Bluewater Forklift
Storage Systems
Block stacking
Wide aisle racking
Cantilever racking
Narrow aisle racking
Automated
Manual
Drive-through/ Drive-in racking
Sliding or Mobile racking
Double deep racking
Push-back racking
Flow or Live racking
Mezzanine
Carousels
Main types of storage systems
Storage Equipment
Bulk Storage/Block Stack
High density storage on the warehouse floor.
Unit loads stacked on top of each other
Best for large quantities of a single SKU (stock keeping unit)
Allowable stack heights (3 or 4)
Low utilization threshold
Storage Equipment
Adjustable Pallet Rack APR
Consists of uprights, beams and back supports
Anchored to floor with adjustable beams
Must know weight capacity, width of rack opening and the distance
between load bearing beams
Flexible and easily reconfigurable
Layer Pallet Pick Half Pallet Pick Full Pallet Pick
Picking Zone (ground
access)
Rack configuration options
Storage Equipment
Cantilever Rack
Storage of long materials such as piping or wood products
High capital cost per square foot
Higher density for multiple SKU’s
Storage Equipment
Drive-in/Drive Through Rack
Similar to pallet racking but the forklift can drive into the rack
High density storage medium for large quantities of single SKUs
Need good quality pallets
LIFO – Drive In
FIFO – Drive Out
Storage Equipment
Sliding Rack or Shelving
Mounted on guides or rails
Highly space efficient
Very effective for small parts and high SKU
Strong medium for slow moving parts
Storage Equipment
Double Deep Rack
High Density Storage medium
Must use reach truck only with extendable forks
Requires multiple pallets of Single SKUs
Dexion
Storage Equipment
Push back racking
Supports slow moving product
Needs same product in the line
LIFO
No individual pallet access
Storage Equipment
Flow or Live Rack
Great for carton flow or piece pick
Many SKU’s in small footprint
Supports high speed and slow moving product
Designed for High speed picking
Storage Equipment
Satellite/Shuttle racking
No aisles
Many pallets in small footprint
Supports high speed and slow moving product
Good utilisation of space at the loading bay
Continuous flow
Storage Equipment Video
Satellite/Shuttle racking
No aisles
Many pallets in small footprint
Supports high speed and slow moving product
Good utilisation of space at the loading bay
Continuous flow
Note: This chart includes an allowance for marshalling areas and cross aisles.
Warehouse Capacity Planning – UK Pallet 1200 mm Entry x 1000 mm Deep
Capacity utilisation
Warehouse managers are tasked with making use of the whole cubic
volume of the warehouse taking into account accessibility, practical
utilisation limits, cost and accountability
Consider introduction of mezzanine floors for example – e.g. space
above dock doors
Courtesy of AWS Ltd and Cisco Eagle
Storage Equipment
47
Carousel/Vertical lift modules
High capacity storage for pick and pack
Brings parts to operator
High speed picking solution if multiple carousels used
Reduction of travel by SKU
| Wide aisle | Narrow aisle | VNA | Drive in | Double deep | Live storage | Mobile racking | |
| Floor space utilisation | 2 | 3 | 4 | 5 | 3 | 4.5 | 4.5 |
| Cubic space utilisation | 3 | 4 | 5 | 3.5 | 4 | 3.5 | 4 |
| Access to each pallet load | 5 | 5 | 5 | 1 | 3 | 4 | 3.5 |
| Speed of access | 4 | 3 | 3 | 2.5 | 3 | 5 | 2 |
| Stock rotation | 4 | 4 | 4 | 1 | 3 | 5 | 3 |
| Stock control and mgt. | 4 | 4 | 4 | 2 | 2 | 5 | 3 |
| Specialised mhe (in terms of cost) | No 5 |
Yes 2 |
Yes 1 |
No 5 |
Yes 3 |
No 5 |
No 4 |
| Ease of re-location | 5 | 4 | 2 | 3 | 3 | 1 | 1 |
| Speed of installation | 5 | 4 | 2 | 3 | 4 | 3 | 1 |
| Beam adjustments | 5 | 4 | 1 | 1 | 2 | 1 | 3 |
| Total | 42 | 37 | 31 | 27 | 30 | 37 | 29 |
Decision table
Advantages/disadvantages – marks out of 5