STORAGE DAN WAREHOUSING

Lely Herlina

@2022
Industri.ft.untirta.ac.id
 Introduction
• Many manufacturing and distribution companies maintain
large warehouse to store WIP and components received
from external suppliers
• Warehousing is a time-consuming activity that does not
“add value” (Waste)
• JIT philosophy suggests that companies should do away
with any kind of temporary storage and maintain a pull
strategy

Industri.ft.untirta.ac.id
 Introduction
• But, due to the need to maintain a sufficient inventory of
items –(unreliability of suppliers), to improve customer
service, respond to their need quickly make it not possible
to completely do away with the temporary storage.
• It indicates the need for establishing warehouses to service
customers despite the lack of value-added services in
many of them.

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Supply chain contex
Outlet Store
WH
WH
Large Retail
Factory
WH
Factory
Small
Factory
Retail

WH

WH Customers

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 Supply Chain Specifics
• Manufacturing company
• Warehouse has little control
over incoming products
• Large retail vs. small retail
customers
Factory
• Average order size
Large Retail • Shipping mode (truckload
vs. UPS)
• Storage/picking
WH
• Customer’s “pull” (large
Small customers can get “special
Retail treatment”)

Industri.ft.untirta.ac.id
 Topics already covered (cont.)

• Warehouses processes and the associated material flow

Replenishment Replenishment

Broken
Case
Reserve Storage Case
Picking
and Picking
Pallet Picking

Accumulation, Sortation & Packing

Direct Direct
putaway putaway
to reserve to primary
Receiving Shipping
Cross-docking
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 Addressing the problem complexity:
Hierarchical Decomposition
• Strategic-level decisions: they have the longer-lasting impact on the
operation of the warehouse, and involve major investment
• process flow design
• equipment selection
• Tactical-level decisions: medium-term decisions which might still
involve significant investment
• sizing of the facility areas and its equipment
• Storage layout
• resolution of organizational issues like the storage and replenishment schemes,
and batch sizing
• Operational-level decisions: Decisions and policies related to the
real-time operation of the facility
• assignment and control problems of people and equipment

Industri.ft.untirta.ac.id
 Warehouse function
• The main function of a warehouse is warehousing –that is the
temporary storage of goods
• Warehouses also perform other functions:
• Provide temporary storage of goods
• Put together customer orders
• Serve as a customer service facility
• Protect goods
• Segregate hazardous or contaminated material
• Perform value-added services
• Inventory

Industri.ft.untirta.ac.id
 Warehouse Functional Areas

Receiving
 Receiving - receive incoming product
 Reserve - store products efficiently
Reserve
(pallets)
Value Add  Value-add - transform products
(labeling, kitting)
Pick-Line  Pick-line - store product so that it can
be picked efficiently (cases/items)
Sort/Accumulate  Pack/ship - package and ship products

Pack/Ship

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 Elements of a Warehouse

 Storage Media
 Material Handling System
 Building

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 Storage Media

 The primary reasons for using storage racks: Maximizing

space utilization in a warehouse.
 Each rack has multiple storage spaces
 The types of storage racks
 Stacking frames
 Cantilever racks
 Selective rack
 Flow rack
 Racks for Automated Storage and Retrieval Systems

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 Storage Equipment

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 1. Block Stacking (No equipment)

 Bulk storage using block stacking can result in the

minimum cost of storage since cubel utilization is
high and no storage medium is required, but material
accessibility is low since only the top of the front
stack is accessible and loads at bottom of a stack
must not require support.
 Storage racks are used when support and/or material
accessibility is required.
 A very basic form of storage, in which objects are
placed on a surface (usually a flat floor) and stacked
on top of one another in blocks

Industri.ft.untirta.ac.id
 2. Selective pallet rack

 Most popular type of storage rack

 Pallets are supported between load-supporting beam
 Special attachment and decking can be used to make the
rack capbale of supporting other types of unit loads besides
pallets (e.g. coils, drums, skids)
 Selective racks used for following types of storage:
- Standard-single-deep storage using a counterbalanced
lift truck
- Narrow-aisle-storage using a narrow-aisle lift truck
- Deep-reach-greater than single-deep storage (tpically
double-deep storage)

#Materi 8_2021
Industri.ft.untirta.ac.id TIN 619307 – Perancangan Tata Letak Fasilitas
 3. Drive-in rack

 Used to provide high density pallet

storage
 Loads are suppored by rails attached to
the upright beams
 Lift truck are driven between the uprights
beams
 Requires similar-width loadas
 Closed at one end, allowing entry from
one end (LIFO)

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 4. Drive-through rack

 Similar to drive-in rack, except

open at both ends, allowing
access from both ends (FIFO)

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 5. Push-back rack

 Used to provide highly accessible carton or pallet

storage
 Load are supported on an incline to enable gravity-
based movement of the loads within the rack (via,
e.g., a gravity roller conveyor)
 Loaded and unloaded at the lower end and closed
at the higher end (LIFO)
 Push-back pallet racks can be used to enable deep-
reach storage without the need for extended reach
mechanisms for loading/unloading

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 6. Flow-through rack

 Similar to push-back rack, except loaded at the

higher end and unloaded at the lower end (FIFO)
 Termed pallet-flow rack when pallets are used
 Typically used in orderpicking operations so that
replenishment does not interfere with picking

Industri.ft.untirta.ac.id
 7. Sliding rack

 Used when only single-deep storage is possible

and space is very limited or expensive
 Sometines referred to as a “mobile rack” or
“moveable aisle” rack
 Expensive compared to other storage racks
 Only one mobile aisle is used to access several
rows of racks
 Location of the aisle is changed by sliding rows of
racks along guide rails in floors

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 8. Cantilever rack

 Loads are supported by two or more cantilevered

“arms” (i.e., horizontal beams supported at onlu one
end)
 Similar to pallet racks, except the front upright and
front shelf beams are eliminated
 Used when there is a need for a full clear shelf that can
be loaded from the front without obstruction from rack
support uprights
 Typically used to store long loads (e.g., bar stock, pipes,
lumber)

Industri.ft.untirta.ac.id
 9. Stacking frame

 Interlocking unit that enable stacking of a

load so crushing doe not occur
 Can be disassembled and stored
compactly when not in used
 Pallet frames can be used to enable
multilevel block stacking

Industri.ft.untirta.ac.id
 10. Shelves/bin/drawers

 Alternative to rack to store small, loose,

nonpalelletized items
 Difficult to automate picking
 Space is frequently underutilized

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 11. Storage carousel

 Carousel consists of a set of vertically or horizontally

revolving storage baskets or bins
 Materials (and the storage medium) move to the
operator, “part-to-man”, for end-of-aisle picking
 Each level of the casousel can rotate independently in
a clockwise or counter-clockwise direction
 Cntrol ranges from manually activated push buttons to
automated computer controlled systems
 Similar to a trolley conveyor with storage baskets

Industri.ft.untirta.ac.id
 12. Automatic storage/retrieval systems (AS/RS)

 Consists of integrated computer-controlled system that

combines storage medium, transport mechanism, and
controls with various levels of automation for fast and
accurate random storage of products and materials
 S/R machine in an AS/RS operates in narrow aisle, serving
rack slots or both sides of aisle; can travel in horizontal
(along the aisle) and vertical (up and down a rack), direction
at same time
 Advantage: fewer material handlers, better matial control
(including security), and more efficient use of storage space
 Disadvantages: high capital and maintenance costs, and
difficult to modify

Industri.ft.untirta.ac.id
 Storage/retrieval systems

Two types of Storage and Retrieval Systems

• Person-to-item:
The storage racks are stationary and a person or machine picks the
items
• Item-to-person
The items come to the end of an aisle and then send them (by an
operator or a transportation mechanism) to their point of use (e.g. flow
racks, food vending machines, etc.)

Industri.ft.untirta.ac.id
 13. Split-case order picking system

 Unlike an AS?RV, a split-case order picking system

enable fully automated picking of individual items
 Two general categories of spit-case order picking
system are robotic based systems and
magazine/dispenser based systems
 Robotic based systems are similar in construction to
robotic pick and place palletizers
 Magazine/dispenser based systems are similar to
vending machines, but larger in scale

Industri.ft.untirta.ac.id
 WAREHOUSE DESIGN ?

 How many and where to locate warehouses?

 Layout of warehouse ?
 Layout & Number of Docks ?
 Rack/ Block Stacking Design ?
 Storage Policies ?

Industri.ft.untirta.ac.id
 WAREHOUSE Location

Three main questions that need to be answered

1. How many warehouses must be built?
2. Where should each warehouse be built?
3. How large should each warehouse be?

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 OVERALL LAYOUT OF WAREHOUSE

Depends on the items stored, space available, height,

storage medium, S/R methods, the layout of road and
rail tracks around the warehouse, and other factors.

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 Typical dock layout

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 Rack Design
• The required length and width of the warehouse
depend on the number of items to be stored, number
of storage spaces required, number of rows and
columns of racks, and height.

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 Standar warehouse design

Industri.ft.untirta.ac.id
 Storage policy

1. Dedicated Storage policy:

• Product is assigned at pre-established set position
• Easy to implement but causes an under utilization

2. Random Storage policy:

• Product allocation is decided dynamically on the basis of:
• Current warehouse occupation
• Future arrival and request-forecast
• Allow a higher utilization of space but requires:
• Each item be automatically identified
• Update database of current position of all items

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 Storage policy

3. Class Based Storage policy:

• Product are divided into a number of categories according to their
demand
• Each category is associated with asset of zones where the goods
are stored according to random storage policy

4. COI (Cube per Order Index) policy:

5. Shared Storage policy:

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