Layout of a unit-load area

Layout of a unit-load area

1. Aisle configuration

   • Cross-aisles
     • Orient aisles to run parallel to the direction of material flow
       • Dual cycle to reflect the interleaving of putaways and retrievals
         • IT support
         • Extra cost for space
         • Receiving and shipping
           • Opposite side
             • Location is less convenient
               • Each pallet must cross the aisle once
           • Same side
             • Near locations are unaffected
               • Far locations less convenient
                 • Pallet crosses the aisle twice
   • Angles aisles
     • Fishbone layout
       • Warehouse larger to compensate the space lost to the additional aisles
         • Efficiency
         • Advantage if the dispatch point is at the center

2. Space

   • Stack height
     • Many pallet positions per ft2
       • Not heavy nor fragile pallets
         • SKUs should be economic
           • Advantages:
             • Easy to store and retrieve
               • Additional pallet positions
                 • Protect product from damage
                   • Safer work environment
   • Lane depth
     • Provides accessibility
       • By storing in lanes, additional pallet positions can share the same aisle and amortize cost
         • Deeper lanes produce more pallet storage locations but they are of diminishing value
           • Total area charged in one lane is k + a/2
             • k = space devoted to storage
             • a = aisle space in front of the pallet
             • Theorems
               • 1- The most space-efficient lane depth for sku i with qi pallets stackable zi high is proof
                 • Ideal lane depth for sku i
               • 2. Floor storage to minimize the average floor space consumed per pallet
                 • floor storage should be configured with lane depth of approximately

3. Labor

   • Warehouse wants many handles/person-hour
     • Increase handles/person-hour by reducing travel time
       • Storage Locations
         • Convenient locations
           • Frequencies of visits are determined by customers orders
             • minimize labor
               • rank pallet positions from least to great cost
               • soonest departure to latest departure
       • Receiving and shipping locations
         • Best location? = depends on the populations of SKU´s passing through the warehouse
           • U-flow
             • receiving and shipping on the same side of the warehouse
             • Provides dock flexibility
             • Allows expansion along other three sides of warehouse
           • Flow-through
             • Receiving and shipping on opposite sides of the warehouse
             • All product flows in the same direction
             • More appropriate for extremely high volume

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