Warehouse Design & Layout - Perancangan Fasilitas pada Warehouse-
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Oleh : Debrina Puspita Andriani Teknik Industri, Universitas Brawijaya e-mail :
[email protected] /
[email protected] www.debrina.lecture.ub.ac.id
Warehouse
Receiving & Shipping operations
Outline www.debrina.lecture.ub.ac.id
Dock locations
Storage operations
Order picking operations
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Mission of A Warehouse www.debrina.lecture.ub.ac.id
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• PERSEDIAAN à penyeimbang dan penyangga akibat adanya perbedaan antara perencanaan produksi dengan permintaan aktual • KONSOLIDASI BARANG à penggabungan barangbarang dari beberapa pabrik atau gudang kecil sebelum dikirimkan • DEPO àGudang penyangga yang mendekati pasar, untuk mempercepat respon supply
Jaringan Distribusi dan Warehouse www.debrina.lecture.ub.ac.id
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Main Functions in the Warehouse www.debrina.lecture.ub.ac.id
Receiving and shipping (penerimaan dan pengiriman)
Identifying and sorting (pengidentifikasian dan penyaringan)
Dispatching ke penyimpanan
Picking the order (pemilihan pesanan)
Storing (penyimpanan)
Assembling the order ( perakitan pesanan)
Packaging (pengemasan)
Dispatching the shipment
Maintaining record (perawatan produk)
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Provide temporary storage of goods Put together customer orders Serve as a customer service facility Protect goods Segregate hazardous or contaminated materials Perform value-added services Inventory
Warehouse Functions
Warehouse Problems www.debrina.lecture.ub.ac.id
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Tinggi bangunan
Storage media yang digunakan
Luas lahan yang tersedia
Barang yang disimpan
S/R methods
Layout gudang tergantung beberapa hal, yaitu:
Jalan/lintasan pada rak penyimpanan
Layout Gudang Secara Umum www.debrina.lecture.ub.ac.id
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Warehouse Design • Location • How many? • Where? • Capacity
• Overall Layout
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RECEIVING & SHIPPING OPERATIONS www.debrina.lecture.ub.ac.id
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Replenishment
Replenishment Reserve storage and pallet picking
Direct put away to reserve Receiving
Case Picking
Broken Case Picking
Accumulation sortation packing and utilization
Cross-docking
Shipping
Typical warehouse functions and flows www.debrina.lecture.ub.ac.id
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The Flow of Material
1. Transportation facilities on one side of building Highway or Railroad
R
S
R
S
R S
Receiving & Shipping Operations (1) www.debrina.lecture.ub.ac.id
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The Flow of Material
2. Transportation facilities on two adjacent sides of building
R
S
R S
R S
Receiving & Shipping Operations (2) www.debrina.lecture.ub.ac.id
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The Flow of Material
3. Transportation facilities on two opposite sides of building Highway or Railroad
R S
R
R
S
S
Receiving & Shipping Operations (3) www.debrina.lecture.ub.ac.id
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1 Determine what is to be received and shipped
2 Determine the number and type of docks
3 Determine the space requirements for the receiving and shipping area within the facility
Receiving & Shipping Space Planning www.debrina.lecture.ub.ac.id
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1. Determine what is to be received and shipped Receiving & Shipping Analysis Chart Company Prepared by
Date Sheet
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Size
Weight
Unit Loads
DescripGon
Raw Materials Plant Supplies
of
Type
Capacity
Finished Goods
6 7 8 9 10 11 Size of TransportaGon Material Handling Frequency Shipment of Shipment Mode SpecificaGons Method Time (unit loads)
Receiving & Shipping Space Planning www.debrina.lecture.ub.ac.id
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2. Determine the number and type of docks Rail docks
The number of docks
Waiting line analysis
Determine the time required to load or unload a carrier
Poisson distribution or Simulation
Time study : work sampling, PMTS, etc.
Truck docks Type of Docks
Drive in docks 900 docks
Receiving & Shipping Space Planning www.debrina.lecture.ub.ac.id
Finger docks
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Minimum Maneuver for R/S Area
Jenis Alat Material Handling
Minimum Maneuvering Allowances (ft)
Tractor
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Platform truck
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Forklift
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Narrow aisle truck
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Hand-lift (jack)
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Four-wheel hand truck
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Two-wheel hand truck
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Manual
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www.debrina.lecture.ub.ac.id
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3. Determine internal receiving and shipping area requirements
Personnel convenience/offices
A receiving hold area
The truckers’ lounge
Trash disposal & recycling bins
Buffer or staging area
Material handling equipment maneuvering
Receiving & Shipping Space Planning www.debrina.lecture.ub.ac.id
Pallet and packaging material storage/palletizing equipment
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DOCK LOCATIONS www.debrina.lecture.ub.ac.id
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Lokasi dan Layout Dock www.debrina.lecture.ub.ac.id
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Dock Levelers
Bumper Pads
Dock Shelters
As the interface between a dock at a given height and variable-height carriers
As the interface between a fixed dock and a moveable carrier
As the interface between a heated/ air conditioner dock and an unheated/non-airconditioned carrier
Dock operations planning www.debrina.lecture.ub.ac.id
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Material flows
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Expansion directions (Receiving and shipping activities)
Modular design of storage/warehouse facilities with expansion alternatives www.debrina.lecture.ub.ac.id
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STORAGE OPERATIONS www.debrina.lecture.ub.ac.id
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• • • • •
Stacking Frames Cantilever Racks Selective Rack Flow Rack Racks for Automated Storage and Retrieval System (AS/ RS)
Storage Medium www.debrina.lecture.ub.ac.id
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Stacking Frames www.debrina.lecture.ub.ac.id
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Cantilever Racks
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Selective Rack www.debrina.lecture.ub.ac.id
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Flow rack www.debrina.lecture.ub.ac.id
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AS/RS (Automated Storage / Retrieval Systems)
www.debrina.lecture.ub.ac.id
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• Person-to-item (fixed) Rak penyimpanan statis (diam) dan orang/ mesin yang mendatangi lokasi barang dan mengambilnya. • Item-to-person (random) Barang yang berjalan dengan menggunakan material handling device (seperti conveyor) menuju lokasi penerimaan yang telah ditentukan. Flow rack merupakan salah satu media yang dirancang menggunakan sistem ini.
Storage and Retrieval Systems (1) www.debrina.lecture.ub.ac.id
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PELAJARI : • Manual S/RS • Semi-automated S/RS • Automated S/RS • Aisle-captive AS/RS • Aisle-to-aisle AS/RS • Storage Carousels • Vertical • Horizontal
• Miniload AS/RS • Robotic AS/RS • High-rise AS/RS (two motors)
Storage and Retrieval Systems (2) www.debrina.lecture.ub.ac.id
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Prinsip yang diperhitungkan dalam perencanaan gudang: Popularity Frekuensi perpindahan barang, masuk (receiving) dan keluar (shipping)
Similarity Utilisasi Item yang Size ruang diterima pengelompo Characteristics termasuk dan dikirim Jenis dan sifat kan luas lantai bersamaan, berdasakan barang yang storage seharusnya ukuran fisik disimpan kemudahan barang disimpan akses bersama
Storage Layout Planning www.debrina.lecture.ub.ac.id
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Randomized storage policy
Dedicated storage policy
Class-based storage policy
Shared storage policy
Storage Policies www.debrina.lecture.ub.ac.id
Cube-per-order index (COI) policy
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Entrance/Exit
FAST MOVING ITEMS
MEDIUM MOVING ITEMS
SLOW MOVING ITEMS
• Dirancangan berdasarkan hukum Pareto: “80% the turnover will be as the result of 20% of material stored”. • Sehingga 20% material yang menentukan tersebut dipertimbangkan untuk disimpan dan diambil dalam jarak yang paling pendek. • Barang yang masuk dalam kategori fast moving diletakkan mendekati pintu masuk atau/dan keluar.
Penyimpanan barang berdasarkan Popularitas barang yang disimpan www.debrina.lecture.ub.ac.id
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190 180 170 160 150 140 130 120 110 100 100 110 120 130 140 150 160 170 180 190
5%
180 170 160 150 140 130 120 110 100 90 90 100 110 120 130 140 150 160 170 180 170 160 150 140 130 120 110 100 90 80 80 90 100 110 120 130 140 150 160 170 160 150 140 130 120 110 100 90 80 70 70 80 90 100 110 120 130 140 150 160 150 140 130 120 110 100 90 80 70 60 60 70 80 90 100 110 120 130 140 150
15%
140 130 120 110 100 90 80 70 60 50 50 60 70 80 90 100 110 120 130 140 130 120 110 100 90 80 70 60 50 40 40 50 60 70 80 90 100 110 120 130 120 110 100 90 80 70 60 50 40 30 30 40 50 60 70 80 90 100 110 120 110 100 90 80 70 60 50 40 30 20 20 30 40 50 60 70 80 90 100 110
80%
100 90 80 70 60 50 40 30 20 10 10 20 30 40 50 60 70 80 90 100
Dock
“Optimum” Dedicated Storage Layout www.debrina.lecture.ub.ac.id
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Barang mudah busuk/tidak tahan lama, seperti ikan, sayur, buah, dll. Media penyimpanan dirancang dengan temperatur yang khusus.
Barang berbahaya/beracun, seperti cat, pernis, bahan kimia yang mudah meledak, dll. Penanganan khusus terhadap barang ini diatur dalam regulasi safety dan harus menempati lokasi yang aman dan terisolir.
Rencana Penyimpanan Berdasarkan Karekteristik Barang www.debrina.lecture.ub.ac.id
Barang yang berdimensi khusus/ tidak standar. Barang yang dimensinya tidak umum baik panjang ataupun luasannya. Sehingga memerlukan rak/ media simpan yang fleksible dari dimensi dan ketinggiannya.
Barang berharga/kecil. Penanganan barang yang mudah dicuri dan bernilai tinggi harus mempertimbangkan penjagaan dan lokasi penempatan yang aman.
Barang yang bersesuaian. Barang yang akan rusak jika ditempatkan berdekatan dengan barang yang mempengaruhinya secara kimia /fisik. Seperti margarin, jika disimpan diruang pendingin bersamaan dengan ikan, maka bau ikan akan mempengaruhi/merusak aroma margarin.
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ORDER PICKING WAREHOUSE OPERATIONS www.debrina.lecture.ub.ac.id
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Work Element
Method of Elimina
Equipment Required Stock-to-picker System - Miniload AS/RS Traveling Bring pick locaGons to picker - Horizontal Carousel - VerGcal Carousel
Computer Aided Order Picking Automate informaGon flow AutomaGc IdenGficaGon System Light-Aided Order Picking VerGcal Carousel Reaching Present items at waist level Person-aboard ASRS Miniload ASRS Sor
Documen
www.debrina.lecture.ub.ac.id
Order Picking Work Elements & Means for Elimination
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Pickers Per Line Items Per Period Per Orders Pick Shi] Discrete Single Single Single Zone MulGple Single Single Batch Single MulGple Single Wave Single Single MulGple Zone-Batch MulGple MulGple Single Zone-Wave MulGple Single MulGple Zone-Batch-Wave MulGple MulGple MulGple Procedure
Methods of Order Picking www.debrina.lecture.ub.ac.id
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• Tompkins, White, Bozer and Tanchoco. (2010). Facilities Planning (4th Ed.). New York: Wiley.
REFERENCES www.debrina.lecture.ub.ac.id
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