Revision Dr. Lum

• U-Shaped Flow

• Straight-Through Flow

• Modular-Spine Flow

• Multi-Story Flow

• good utilization of dock resources (shared doors for inbound and outbound activities)

• makes cross-docking easier (inbound and outbound activities right next to each other)

• good lift truck utilisation (putaway and retrieval trips are combined)

• opportunities to expand in 3 dimensions

• better security (entry/exit can be controlled from one side)

• A products can be stored in prominent position

efficient operations due to direct product flow

suitable for high throughput warehouses

inbound and outbound activities can not be combined -> additional resources

difficult to take advantage of ABC storage

Inbound

• receiving

• putaway

• storage

Outbound

• order picking

• sortation & accumulation

• unitising & shipping

• unloading of products or goods from the carriers

• verification against the documents

• preparing products for putaway and storage

• updating receiving and putaway transactions in the system

Receiving Scheduling (know when to order)

• schedule inbound loads to match outbound requirements

• proper scheduling helps to balance the use of resources

Pre-Receiving (know the details of the good arriving)

• capture required information in advance for receiving and putaway

• minimises holding time at the receiving area

Receipt Preparation (know what to do when goods arrive)

• preparatory activities at the time of receiving

• obtain information on product processing for storage in advance

• pre-packaging, apllying labels & tags etc.

Direct Putaway

• putaway directly to primary or reserve locations

• designated location is reserved

Directed Putaway

• WMS calculates ideal storage location to maximise utilisation and productivity

• putaway operator is directed by WMS

Batched and Sequenced Putaway

• sort inbound goods by zones and locations sequence

• “Zwischenlager”

1. Single Order Picking

2. Batch Picking

3. Zone Picking

One (or more) order picker(s) is/are assigned to a single customer order

• suitable for low volume

• suitable for handling urgent orders

Multiple customer orders for the same items are batched together and picked during a picking tour

The items are then taken to the staging area to be sorted and combined with other items of the same order before packing

Separates customer orders into fixed or variable zones

Order picker is assigned to a designated zone

• consolidating shipments from different sources without putting into storage and delivering to the customer directly

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• scheduling inbound deliveries to arrive at warehouse JIT

• requires large staging areas to sort inbound materials

• shift of focus from “Supply Chain” to “Demand Chain”

• bypassing the normal storage & order-picking cycles

Pre-Distribution cross docking

• vendor prepares product (i.e. labeling) according to customer

• products are directly transferred in cross docking operation

• customer information is totally available to vendor

• difficult to coordinate

Post-Distribution cross docking

• customer information are handled centrally by distributor

• same for labeling, verification and so on

-> high labor costs

• high demand with low variance

  -> match supply and demand

• easy to handle

1. Profile: family mix distribution, handling unit mix distribution

2. Benchmark

3. Simplify: eliminate as much work content as possible

4. Computerize

5. Mechanize: mechanized material handling

6. Layout

7. Humanize