Racking In The Foodservice Warehouse

Racking In The Foodservice Warehouse

W. Frank Dell CMCPresident

DELLMART & Company125 Hardesty RoadStamford, CT 06903

AgendaAgenda

INTRODUCTION RACKING OPTIONS MECHANIZATION OPTIONS EQUIPMENT OPTIONS DESIGN ISSUES SUMMARY

DELLMART & COMPANYMANAGEMENT CONSULTANTS

ObjectivesObjectives

Explore different types of racking or storage mediums

Understand the advantages and disadvantages of each type

Review the supporting equipment

Warehouse Design Rational IncludeWarehouse Design Rational Include

Store Capacity Selection Slots Labor Productivity Through-Put

Terminology For Warehouse ProcessesTerminology For Warehouse Processes

Inbound Receiving Put-Away

Outbound Replenishment Selection Loading

Procurement’s Impact On Warehouse RequirementsProcurement’s Impact On Warehouse Requirements

Storage Capacity Selection Slots Receiving Doors & Dock Space Storage Type

Pallet Size Should Be Determined Jointly By Buying And WarehousingPallet Size Should Be Determined Jointly By Buying And Warehousing

Cycle Stock = Pallet Quantity

Pallet Quantity =

Ordering Concepts Fixed Review Just In Time

2 X Put Away Cost

Holding Cost

Customer’s Impact On Warehouse RequirementsCustomer’s Impact On Warehouse Requirements

Sales Volume Order Size Pick Density Number of Orders Shipping Doors and Dock Space

Direct Labor FundamentalsDirect Labor Fundamentals

Every task has a fixed time component Travel Standards

Walk Ride LIft

Case Handling Standards Case Cube Weight

AgendaAgenda

INTRODUCTION RACKING OPTIONS MECHANIZATION OPTIONS EQUIPMENT OPTIONS DESIGN ISSUES SUMMARY

DELLMART & COMPANYMANAGEMENT CONSULTANTS

Floor StackFloor Stack

Usage - Selection, reserve and bulk storage Application

Large case cube High velocity Low roof

Floor space utilization2 Replenishment per 3 selection palletsFlexible deepMinimal capital cost

Advantages

Height restriction (Max. 3 pallets high)Product rotationProduct damage

Disadvantages

Single Deep One High SelectSingle Deep One High Select

Usage - Selection floor slot with reserve overhead Application

Large case cube Fast seller

Simple to manageGood height utilization

Advantages

Reduce slot cube utilization

Disadvantages

Single Deep Two High SelectSingle Deep Two High Select

Usage - Selection floor slots with reserve overhead Application

Medium cube and velocity Small cube and high velocity

Increase selection slotsIncrease selection densityReduce walk time

Advantages

Reduce cube utilization

Disadvantages

Single Deep Three High SelectSingle Deep Three High Select

Usage - Selection floor slots with reserve overhead Application

Small cube Slow velocity

Increase selection slotsIncrease selection densityReduce walk time

Advantages

Reduce cube utilizationReduce selection capacitySlower replenishment

Disadvantages

Single Deep Hand StackSingle Deep Hand Stack

Usage - Selection floor slot with no reserve storage Application

Small cube Very slow velocity Broken case items

Increase selection slotsIncrease selection densityReduce walk time

Advantages

Reduce cube utilizationReduce selection capacitySlower put-awayIncrease rotation problemsIncrease selection errors

Disadvantages

Case Flow RackCase Flow Rack

Usage - Selection with reserve in lane and bulk storage overhead

Application Case cube less than 1 Case velocity less than 11

High selection densityKeeps family groups together

Advantages

Must be linked to buying

Disadvantages

Double Deep One High SelectDouble Deep One High Select

Usage - Selection floor slot with reserve overhead and behind

Application Large case cube Fast seller

Good storage capacity

Advantages

Difficult to replenish and put-awayIncrease rotation problems

Disadvantages

Drive in RackDrive in Rack

Usage - Selection floor slots with reserve overhead Application

Large case cube High Velocity Buying restriction

Multiple selection slotsMaximum selection capacity

Advantages

Increase rotation problemsCreates honey combing

Disadvantages

AgendaAgenda

INTRODUCTION RACKING OPTIONS MECHANIZATION OPTIONS EQUIPMENT OPTIONS DESIGN ISSUES SUMMARY

DELLMART & COMPANYMANAGEMENT CONSULTANTS

Pick To BeltPick To Belt

Application Medium size cases Fast and medium velocity

High selection rateControlled walkBatch select

Advantages

Requires sorting stepMust walk entire systemNon-conveyable cases

Disadvantages

CarouselCarousel

Application Smaller cases Slow velocity

Random selectionReduce travel

Advantages

Lose overhead storageLimitation on case sizeSlow replenishment

Disadvantages

CartracCartrac

Application Medium and large cases High velocity with multi-carts

Reduce travelBatch selection

Advantages

Lose overhead storageDifficult to replenish

Disadvantages

Program Item Retrieval (PIR)Program Item Retrieval (PIR)

Application Small and medium cases Slow velocity

Increase selection slotsRandom slotsBatch select

Advantages

Require sorting stepMachine paces travelSlower put-away

Disadvantages

AgendaAgenda

INTRODUCTION RACKING OPTIONS MECHANIZATION OPTIONS EQUIPMENT OPTIONS DESIGN ISSUES SUMMARY

DELLMART & COMPANYMANAGEMENT CONSULTANTS

Fork LiftsFork Lifts

Counter balance - wide aisle Straddle - narrow aisle Stand-up versus ride

Fork Lift AttachmentsFork Lift Attachments

Pallet forks Slip sheet or push-pull Clamp Reach

Single Pallet JackSingle Pallet Jack

Dock Jockey Put-away into floor slot Put-away transport Selection

Double Pallet Jack (Long John)Double Pallet Jack (Long John)

Put-away transport Selection

Single orders Batch orders

TuggerTugger

Carts or trucks Radio control

AgendaAgenda

INTRODUCTION RACKING OPTIONS MECHANIZATION OPTIONS EQUIPMENT OPTIONS DESIGN ISSUES SUMMARY

DELLMART & COMPANYMANAGEMENT CONSULTANTS

Narrow Versus Wide AisleNarrow Versus Wide Aisle

Less floor square feet Greater cube utilization Facilitates 2 side selection Increases congestion and interference Increases damage

Slot ColumnSlot Column

Spacing Maneuvering room Product Pallet Bar

Bury columns Number of slot types

Product

Rack Bar

Pallet

Rack Bar

Cross BarsCross Bars

Pair weight Adjustability

Height Versus FloorHeight Versus Floor

Land cost 24 foot rule

SlottingSlotting

Family grouping Velocity Customer orders Density

Layout Check ListLayout Check List

Dock space Employee area and facilities Battery charging area Repair and maintenance area Damage and return processing

AgendaAgenda

INTRODUCTION RACKING OPTIONS MECHANIZATION OPTIONS EQUIPMENT OPTIONS DESIGN ISSUES SUMMARY

DELLMART & COMPANYMANAGEMENT CONSULTANTS

SummarySummary

Plan 5 years into the future Rank design rationale Test alternatives with labor models Perform quarterly maintenance

Thank for Providing SlidesThank for Providing Slides

Clark

Crown

Hi-Line

Hyster

Interlake

Raymond

SI Handling

White

Yale