Warehouse Management: Layout is the key of success

Warehouse Management: Layout is the key of success


In the warehouse management is emphasized especially in the placement of goods in the warehouse. If the irregular placement of the item it will have an effect on the length of picking process, inventory accuracy can not reach 100%, dead stock, overstock, under stock. Overstock raises a cost called Inventory Carrying Cost. Inventory carrying costs are the costs incurred as a result of excessive inventory in the warehouse so as to make the cost of storage, cash flow so disturbed, warehouse efficiency is low. Excessive inventory that could cause the goods damaged and expired so that there will be an even greater cost of having to bear the loss of damaged goods. Understock or out of stock can lead to loss of sales opportunity. The duration of picking cause delays in delivery to the customer. In the end customer who will be harmed that will affect the business opportunity and customer satisfaction for our service. It all comes back to "maximize" customer service.

Efficient warehouse usually do things like this:

Provide timely services
The existence of clear stuff, easily and quickly searched
Minimizing the movement in and out of the warehouse and the cost of goods in the warehouse.
Building a good line of communication with the customer
layout

There are two systems in the warehouse for placement of goods that

Fixed Location System
Floating Location System
For setting items there are some guidelines that should be followed, namely:

Full Case and area separation Partial area.
Grouping by ABC
Grouping similar items
Grouping items the same function
Grouping items interconnected adjacent or one area
Grouping of fast moving goods in one area
Separation of goods Return / reverse stock in a separate area
Separation of goods according to the Project / Customer
fixed Location

is the placement of goods in the designated location for the type of item / specific products only and should not be filled with other products. Warehouse using this system the warehouse usually small and do not use the Warehouse Management System (WMS) where the volume of goods in and out of small and few SKUs (Stock Keeping Units). The warehouse used to wear in the Excel grid placement / location or recording.

There are weaknesses in the use of this system, where the system we must provide / allocate space for each product. By way of allocation, then the automatic warehouse will not be efficient in the utilization of space.

Floating Location System

Floating This location is a system of placement of goods can be placed at different locations in the warehouse. Warehouse using this system is a modern warehouse and computer-based, usually wearing a Warehouse Management System (WMS). There are several WMS is used by several companies, namely Live Inventory (PT IMS Logistics), FMGPro, Manhattan, etc. All of these systems use barcode as the ingredients and integrated in all their branches, even Live Inventory has started the implementation of RFID in the year 2011. The WMS will tell which ones will be the location of the goods or PIC Warehouse can put in any place because the transfer or placement will direcord in the system with barcode scanning location of goods. So, no more items tucked in the shed.

By using this system, all items will be identified with a good location and shelf placement because they use barcoding system in the identification and location of goods, no longer using Excel or manually. This system is the most efficient system for the utilization of space in the barn very well. No more empty space, all will be filled. But it also would be nice placement of each type / same product into one location. This is to make it easier for the picking because it is in one location.

If fixed location system, we have to make a longer next to or have to shift goods to the place next to the other, if the space allocation is full, it automatically takes more energy and inefficient.

With floating location system and warehouse management system, the goods can be placed anywhere as long as the site is updated in the system. So all goods must be attached barcode containing a unique code / packing list and the case of the goods. Functions that the barcode will be the identification of the goods. WMS require barcode scanning barcode of the item and the location / grid placement of goods. Example: Soap A packing list has to be placed on the grid 039308001 A01B.

Figures 039 308 001 001 The case number is reflecting, in front of 001 can be designed itself as needed example of the State, year of manufacture, batch number, expiry date, etc.

Grid A01B is the A01 in grid A number 01, while the letter B behind is in subgrid B. subgrid I will explain below in gridding SYSTEM.

How to scanning:

Scan barcodes first packing list
Scan Barcode Location A01B
The WMS will then be updated that the goods 039308001 description Soap Type A number of 100 pcs are in A01B location. If the request for picking out, it has shown the grid location of the goods.

gridding SYSTEM

A good warehouse must have a grid / locations within the warehouse that has been mapped to the placement of goods. Gridding better system is to divide the warehouse like a chessboard. One Grid normally sized 3mx3m. One grid is further divided into 3 sub-grids, namely A, B, C.

Subgrid function is to focus the search location of the goods. 1 grid is a 3 × 3 m = 9 square meters, if one subgrid only 1 × 3 = 3 square meters. Picker will be more time consuming if necessary to find stuff in 9 square meter than 3 square meters. With search subgrid goods faster because the search scope is smaller than 9 square meters should seek.

Example: searching for items with the Packing List 005 in the grid A01. 9 square feet when completed goods on pallets measuring 1.2 × 1.2m to minus 60 cm to the way it has been calculated how many pallets, pallet 20 when the packing list, then stay multiplied. Let's just 6 multiplied by 20 then 120 pallet packing list should be sought, but if only subgrid 3 square meters, only 3 pallet, or even just 2 pallets only. Faster search.

WAREHOUSE BASIC LAYOUT

For setting items there are some guidelines that should be followed, namely:

Separation areas and areas Partial Full Case

Full Case is the goods have not been taken at all and still in original packaging or still in one palette. Example: a pallet containing 10 cartons. It counted whole case. Placement advised whole case closest to the staging / outbound picking area to speed up the space into account of course.

Partial Case is the item has been taken. Example: a pallet contains 10 cartons, taken 1 carton, then pallet was already counted one partial. Then the placement will be moved to the partial area. Racking is usually placed as a partial area provided it is not too high because if it is too high it requires more effort should be put on the stairs and as prone to safety.

This separation is intended to allow the picker is not the origin of the whole case and take picker should spend the first item that has been broken so that the goods are not taken all intact and be partial all. It would make a mess and FIFO inventory will be not running correctly. Imagine if all the cartons were opened and taken a little but not spent the first carton, then it will all fall apart.

Grouping by ABC

group A

Usually a number of ± 20% of the total elements and represent ± 80% of the total value. This stuff is very important and should be monitored this stock. Inventory accuracy must be 100% for A items are high value items

group B

Usually amounts to ± 30% of the total items and represent ± 15% of the total value. Stock amounted to more than A items but less than C items. Inventory accuracy must be 100% because this stuff Medium Value Item.

group C

Usually amounts to ± 50% of the total elements and represents the total value of ± 5%. C This item is also very important although low value. Normally stocked in large quantities and usually not too overlooked in 100% inventory accuracy because this stuff Low Value Item.

Grouping similar items

Should the arrangement of the same type used in one area. This is to facilitate and speed up the picking. If you put different places, so if in one place it is up, then the picker will take longer for the road to another place and very inefficient.

Grouping items the same function

Example: Shampoo the various variants into one area, with its variants soap, toothpaste, detergent, etc. If in telecommunications such as: antenna with its variants, BTS with its variants, with various types of cable rack.

Grouping items interconnected adjacent or one area

Example: If in the telecommunications industry, the customer definitely order the antenna with ODU, IDU, feeder kits, Jumper Cable. Each item collected adjacent but should still be separated by type or by Item Number. This is to speed up the picking because it is appropriate that each picking this flow definitely need some of the items.

Example: Shampoo bottles, shampoo sachets with various variants are placed adjacent to one lane, is to facilitate the retrieval of shampoo with a wide range of variants and sizes.

Grouping of fast moving goods in one area

Fast moving goods are usually placed in near staging area / outbound area which must be kept in mind when in one of the lanes filled with all the fast moving goods, there will be a bottleneck if during peak time. This will make the picker can hardly walk and could not fast because of blocked her and abuse, such as road traffic, very inefficient. Example: Unilever that the majority of fast moving goods, it must be interspersed with slow-moving goods between the fast moving to reduce the bottleneck.

Separation of goods Return / reverse stock in a separate area

Goods return / reverse stock is returned by the outlet goods to the warehouse and to be returned to the principal or to be burned. Even this return of goods can be divided into items that can be sold back (back because the outlet wrong order) term Good Can Resale, Broken / BS term in the market, but will be recycled, and the last, the return of goods that will surely be destroyed. This area is separated from other goods, if not, there will be confusion later.

Separation of goods according to the Project / Customer

This separation usually occurs in the 3PL warehouse, such as PT Tiga Pilar Logistics, PT IMS Logistics, or any other 3PL. Usually they have a lot of customers and a lot of projects. This is to avoid the same stuff used by another customer or by other projects. Example: A customer can have many projects. 3PL customers have many projects a, b, c, d. Usually the projects are divided per user / per customer. Example: Huawei has many projects, Telkomsel, HCPT, NTS. Automatic goods stored in the warehouse have many similarities. It also should not be mixed because each user has purchased goods respectively.