Ankit Singhvi Mahipatraj - GroupAssignment_Group2

8/18/2019 Ankit Singhvi Mahipatraj - GroupAssignment_Group2

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CASE: Arkansas Distribution Centre

Group No. 2 CEO Ankit Singhvi Mahipatraj

Date 21 th March 2016 Members Aditya GhuleRagini SinghAnanthu Nimmy RajuPadmapani Shivsaran

1. Warehouse SizeA. No of Carton on a pallet !!!"#npallet"c#m$

N# #% cart#ns per pallet & ''"

(here are ' layers #% cart#ns !ith each layer c#nsisting #% 11 cart#ns"

. !otal Stora"e #apa#it$ of the Warehouse:

Pallets per )ay & 2N# #% )ays & *N# #% pallets in a rack & *+2 & ,N# #% cart#ns in a rack & , + ''

& 616 (he current %#recasted sales per annum !ith#ut c#nsidering the pr#ducts that are cr#ss d#ckedis 16-6'*"

(he !areh#use is e.pected t# gr#! at / per annum" #nsidering a peri#d #% 10 years the%#recasted sales per annum !ill gr#! t#3

16-6'* + 140"0/$ 510& 26660'"'

#!ever the !areh#use handles cart#ns re7uired t# satis%y a demand %#r - m#nths"


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D. Warehouse Size:

=ength #% !areh#use & /9/00 mm;readth #% !areh#use & -1-/0 mm

eight #% !areh#use & 12/00 mm (#tal Area #% >areh#use & -1-/0+/9/00 & 1,6/-2/000 s7"mm & 1,6/"-2/ s7"mA##or&in" to Richards 201*$

A survey )y ran?eld @niversity ;aker and Per#tti 200,$ sh#!ed that3/2 #% the !areh#use ##r area is typically used %#r st#rage"1' %#r the pick8pack #perati#n"' %#r receiving and despatch"' %#r valueBadding services"' %#r areas such as )attery charging empty pallet st#rage and #ther uses"

St#rage ##r Area & /28100 + 1,6/"-2/ &/ . /

Pick8Pack8S#rt Area & 1'8100 + 1,6/"-2/ &01 .123

Receiving and Cespatch Area & 168100 + 1,6/"-2/ &4 5.634

r#ss C#cking Area & '8100 + 1,6/"-2/ &102.3 4;attery haring Dmpty pallets st#rage and #ther uses & '8100 + 1,6/"-2/ &102.3 4

4. Stora"e Con7"uration:

(he num)er #% cart#ns handled currently is /''*- and the num)er #% cart#ns t# )e handled in10 years: time !ill )e 9*0/'" #!ever the cart#ns received %r#m - suppliers !ill )e cr#ssd#cked directly as the pr#ducts %r#m these suppliers are shipped t# #ne cust#mer #nly" (hey !illn#t )e st#red in the !areh#use" (here%#re the num)er #% cart#ns t# )e st#red in the !areh#usecurrently is *0919 cart#ns and in 10 years: time it !ill )e 666/- cart#ns" (here%#re the rackshave )een designed s# that it can st#re 666/- cart#ns"

(he st#rage c#n?gurati#n in the !areh#use !ill )e such that there !ill )e a dedicated st#ragespace %#r all the pr#ducts" (he pr#ducts !ill )e st#red in the racks depending #n the demand"

(he pr#ducts !ill )e placed in such a !ay that the pr#ducts having highest demand !ill )eplaced in such a !ay that the distance )et!een them and the s#rting area is reduced" (he aim ist# reduce the distance )et!een the pr#ducts having the highest demand and the s#rting area)ased #n the assumpti#n that the num)er #% times the supplier ship the pr#ducts is less than thenum)er #% times cust#mers place #rder" Als# this reduces the lead time a%ter the receipt #% thecust#mer #rder" (he cust#mers can place multiple #rders in a given am#unt #% time )ased #ncust#mer re7uirements and suppliers ship the pr#ducts %#r these multiple #rders in #ne shipment

(here%#re the pr#ducts are placed s# that the distance during s#rting is reduced" (he pr#ducts!ith higher demand are placed #n the racks t# the right #% the lay#ut"

(he pallets received )y suppliers can have all the cart#ns c#nsisting #% single pr#ducts #r cart#ns#% multiple pr#ducts" #!ever suppliers cann#t mi. pr#ducts #n a pallet greater than 6 cart#nsper #rder" (here%#re the pallets that have cart#ns #% multiple pr#duct !ill )e )r#ken )ulk and thecart#ns !ill )e st#red in the areas designated %#r the individual pr#ducts" (hese pr#ducts can )ethen taken directly t# the s#rtati#n system !hen cust#mer #rder arrives"


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(he details #% num)er #% cart#ns shipped )y each supplier per annum in three m#nths and thenum)er #% pallets shipped %#r each pr#duct per three m#nths have )een pr#vided in the e.celsheet"

0. Material ,an&lin":

Acc#rding t# E(he (ypical >areh#use B >hat it is >hen it !as )uiltE 2016$ 6* !areh#use in@"S"A" are larger than 2/000 s7uare %eet" (here%#re it !as decided t# have a !areh#use #% 19-*2"'/ s7uare %eet 1'9' s7 m$" (his area #nly includes the area inside the !areh#use" D.traspace !ill )e re7uired #utside the !areh#use %#r truck terminals" (he height #% the !areh#use

!as selected acc#rdingly s# that in the given area all the pr#ducts can )e st#red" (he heightselected 12/00 mm"

>ith the a)#ve menti#ned height #% the !areh#use Reach (ruck C can )e selected %#r materialhandling"

Speci?cati#ns #% Reach (ruck C3

1$ Ma.imum li%t height #% 10000 mm %#r picking"

2$ Minimum aisle !idth re7uired is 2,/0 mm"

-$ Price is F/0000"

As the distance )et!een the rack )eams is 2'*- mm and there are * )ays the ma.imum heightat !hich the %#rkli%t !ill have t# #perate is ,229 mm !hich is !ell !ithin the 10 000 mmma.imum height" As there is a tradeB# )et!een the height #% the !areh#use and thec#mple.ity and c#st #% material handling e7uipment used the height #% the !areh#use is keptsuch that the Reach (ruck can )e used" (he price #% the Reach (ruck C is F /0 000 !hich standsat an average i% c#mpared t# #ther truck" (here%#re s# as n#t t# increase the c#st andc#mple.ity #% material handling the height #% the !areh#use and hence the %#rkli%ts areselected"

(he material handling can )e d#ne !ith v#ice picking" H% the #rder %#r a certain pr#duct c#ntainslarge num)er #% cart#ns then the entire pallet !ill )e taken t# the s#rting area" Hn the s#rtingarea the re7uired num)er #% cart#ns can )e rem#ved and c#ns#lidated !ith #ther #ut)#undpr#ducts t# the retailer" H% the #rder %#r a certain pr#duct has #nly less num)er #% cart#ns thenthe re7uired num)er #% cart#ns can )e rem#ved %r#m the racks itsel% and taken t# the s#rtingarea t# )e c#ns#lidated %#r #ut)#und #rders"


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ASRS !ill n#t )e used in the !areh#use as the material handling t# )e d#ne is in the %#rm #% cart#ns" As the ASRS is used %#r pr#ducts that are relatively small in siIe and re7uire largeam#unt #% s#rting t# )e d#ne the ASRS is n#t %easi)le %#r material handling in this !areh#use"

6. Warehouse Mana"ement S$stem:

A !areh#use management system !ill )e used t# c#B#rdinate all the activities in the !areh#use%r#m receiving t# shipping" (he >MS can )e integrated !ith the DRP t# have an allBr#und vie! #% all the pr#cesses taking place" (he c#mple.ity #% the >MS !ill )e l#! as the siIe #% the

!areh#use is less than */00 s7 m SiIe #% !areh#use is 1'9' s7 m$ ;erg 201*$ (he >MS system !ill ena)le central management #% all tasks including tracking invent#ry levelsand availa)ility #% st#ck %#r day t# day #perati#ns Richards 201*$" (he >MS !ill guide the#perat#r in v#ice picking #perati#ns put a!ay #perati#ns and in the s#rtati#n system as !ell" Ht!ill als# schedule the in)#und and #ut)#und trucks and help in cust#mer managementin%#rmati#n management and yard management"

Als# the aut#matic s#rting #n the c#nvey#r )elt !ill )e integrated and carried #ut thr#ugh the>MS"

3. Warehouse Operations:

A. %e#ei8in"Suppliers send their trucks !ith %ull and partial pallet l#ads depending #n purchase #rders" (hesupervis#r #% the !areh#use veri?es the transp#rt d#cuments" Jnce the d#cument veri?cati#n isd#ne g##ds %r#m the trucks are unl#aded in the staging area #% !areh#use and are taken t# thest#rage l#cati#ns in the !areh#use"

. 'ut A9a$

(he #perat#r identi?es checks and #rganiIes the materials #n pallets" (he actual st#ck 7uantityis rec#rded in the >areh#use Management System" A uni7ue c#de is printed #n the la)elpr#vided !ith a )ar c#de" (he >MS !ill scan the )ar c#de and guide the #perat#r t# put a!ay

the pallet in a dedicated l#cati#n #% a !areh#use"C. 'i#kin"

Picking activities #% l##se g##ds are per%#rmed !hen #rder %#r a certain pr#duct has less num)er#% cart#ns" H% the #rder %#r a certain pr#duct has large num)er #% cart#ns then entire pallet ispicked" (he #rder is picked and sent t# the s#rting area %#r c#ns#lidati#n #% #ut)#und #rders"Pr#ducts !ith small #rders can )e placed in racks at accessi)le l#cati#n !hereas %ull pallet #rderscan )e racked at a higher l#cati#n in a !areh#use" (he pallets picked %r#m the !areh#use inupdated in the >MS"

D. Sortin":

Jnce the cart#ns are unl#aded %r#m the pallets and placed #n the c#nvey#r )elt the cart#ns !ill)e s#rted using aut#matic s#rting system )ased #n the retailer t# !h#m the cart#ns have t# )eshipped" (he la)#ur !ill rem#ve the cart#ns %r#m the c#nvey#r )elt and place it #n the pallet %#rshrink !rapping"

E. 'a#kin"

(he pallet !ill )e shrink !rapped and )e ready %#r dispatch t# the retailer" A )arc#de !ill )eplaced #n the pallet t# identi%y the c#ntents in the pallet and the retailer t# )e shipped t#"

*. Shippin"

Jrders are l#aded #n the truck ass#ciated t# a speci?c shipment" (he )ar c#de is read !hilel#ading them in truck" (he activity g#es #n until c#mpleti#n #% the shipment" (he supervis#rc#n?rms c#mpleti#n #% the shipment and validates the departure #% the truck"

/. +abour:


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(he num)er #% cart#ns that need t# )e handled per day is ,'/ cart#ns" (he #perati#ns thatre7uire la)#ur is unl#ading put a!ay s#rting packing and l#ading"

Assuming that 2 minutes is re7uired %#r handling each cart#n in v#ice picking in the !areh#usethe n# #% cart#ns that can )e picked in an h#ur is -0 cart#ns" (here%#re in a ' h#ur shi%t thenum)er #% cart#ns that can )e handled )y a la)#ur is -0 + , & 210 cart#ns" Num)er #% la)#ursre7uired t# handle ,'/ cart#ns is * la)#urs"

Jne la)#ur is re7uired t# #perate the %#rkli%t" (he same la)#ur !ill )e used t# put a!ay the

pallets in racks" (!# la)#urs !ill )e re7uired t# run the s#rting #perati#ns"

Jne la)#ur !ill )e re7uired t# l#ad the pallets in the trucks"

(!# supervis#r !ill )e there t# manage the entire #perati#ns #% the !areh#use"

(here%#re there !ill )e eight la)#urers and t!# supervis#rs t# run the #perati#ns #% the!areh#use"

. 'reliminar$ #osts:

(he preliminary c#sts %#r the !areh#use includes the c#st #% land c#st #% %#rkli%ts c#st #% racksc#st #% e7uipment %#r shrink !rapping c#st #% the !areh#use management s#%t!are c#st #% thec#nvey#r )elt and aut#matic s#rtati#n system c#st #% )arc#de printer and scanner" (!# %#rkli%ts!ill )e purchased as e.tra %#rkli%t !ill )e re7uired !hen the #ther %#rkli%t is charging" Als# #ne%#rkli%t !ill )e used %#r l#ading and the #ther %#rkli%t !ill )e used %#r unl#ading"

,0 #% the c#sts !hile c#nstructing a !areh#use c#mes %r#m c#st #% c#ncrete steel siteutilities earth!#rk design %ees r##?ng and ?re pr#tecti#n E;uilding a >areh#use >ith#utG#ing ;r#ke B Hn)#und =#gisticsE 2016$"

Re%erences3

1" Richards G" 201*$" Warehouse Management. =#nd#n3 K#gan Page =imited"

2" EP##led >##d ;l#ck Pallet B N#rth American Standard *, L *0 Hnches$E" Chep.com " N"p"2016" >e)" 20 Mar" 2016"

-" E>hat Hs >areh#use Management System >MS$ B Ce?niti#n %r#m >hatis" #mE"SearchManufacturingERP " N"p" 2016" >e)" 21 Mar" 2016"

*" E/ (ypes J% Packaging e)"21 Mar" 2016"

6" E;uilding A >areh#use >ith#ut G#ing ;r#ke B Hn)#und =#gisticsE" Inboun logistics.com "N"p" 2016" >e)" 21 Mar" 2016"

Ankit Singhvi Mahipatraj - GroupAssignment_Group2

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