Warehouse/distribution Center Layout
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A well-planned warehouse layout will help you reduce operating costs by improving warehouse processes and inventory control. In this course, you will learn to apply field-proven techniques, which focus on layout planning, methods selection, space optimization, and material handling to make your layout the most efficient it can be. Extensive use of cases studies that are adapted from real situations and projects is incorporated in the course. Additionally, you are encouraged to bring challenges from your workplace for consideration and analysis.
What You Will Learn
- Systematic Layout Planning (SLP)
- Profiling and inventory analysis
- Handling and storing equipment
- Flow of materials analysis
- Estimating space requirements
- Material handling methods
How You Will Benefit
- Improve throughput with systematic layout planning.
- Reduce handling costs in storage and order picking.
- Group materials for efficient handling and storage.
- Plan for expansions and new facilities.
- Improve the performance of warehouse and distribution facilities.
- Increase layout planning productivity and effectiveness.
- Offer practical approaches to storage, order picking, packing, material movement and physical control.
- Streamline material flow in warehouses/distribution centers.
- Typical approaches to layout planning
- Three fundamentals of layout planning
LAYOUT PLANNING CASE EXERCISE
- A six-step simplified planning procedure
- Relationship charts and diagrams
- Hands-on case exercise in warehouse layout
SYSTEMATIC LAYOUT PLANNING (SLP)
- The four phases of every layout project
- Systematic planning procedures
- Gathering and projecting key input data
PROFILING AND INVENTORY ANALYSIS
- Activity and order profiles
- Inventory profiles
- Zoning and picking methods
- Matching your methods to inventory levels and flows
- Storage capacity calculations
HANDLING AND STORAGE EQUIPMENT
- Unit load handling and storage
- Case and item picking and storage
- Simple and complex equipment
METHODS SELECTION CLASS EXERCISES
CLASSICAL LAYOUTS AND FLOW PATTERNS
- Commodity, activity, and other storage zones
- Basic flow patterns and their benefits
- Charting your operations
- Defining your activity areas
FLOW OF MATERIAL ANALYSIS
- Ways to measure and visualize material flow
- The quantified flow diagram
- Guided application in flow analysis
- Combining flow and other-than-flow relationships
ESTIMATING SPACE REQUIREMENTS
- Five ways to establish space requirements
- Short-range and longer-range space projections
- Case exercises in estimating space requirements
- Balancing space required to space available
FACILITY PLANNING ISSUES
- Adjusting for physical features of the facility
- The impact of utilities, lighting, HVAC, and other specialized requirements
- Rack and aisle orientations
WAREHOUSE LAYOUT AND MATERIALS HANDLING CASE EXERCISE
- Team exercise to improve an existing layout
- Rearrange to reduce material handling effort
- Layout considerations other than material flow
EVALUATION OF ALTERNATIVE PLANS
- Costs and intangibles
- How to select the best overall layout
- Rack storage areas
- Shelving arrangements and slotting
- Dock areas
- Application of SLP to equipment layout
DISTRIBUTION CENTER PLANNING CASE PROBLEM
- Application of techniques from days 1 and 2 to a distribution center expansion
- Organizing the project
- Developing a preliminary arrangement
- Integrating storage and handling methods
- Improving the preliminary plan
- Responding to changing and unforeseen requirements
ORGANIZING YOUR LAYOUT PROJECT
- Recap of phases, steps, and planning documents
- Working forms and templates for your next project
Who should attend
This course is designed for industrial engineers and systems analysts, warehouse supervisors and team leaders, warehouse/distribution center managers, logistics and supply chain planners, planning teams for new or expanded facilities, and leaders of supply chain and lean initiatives.