There are so many types, variations, and factors involved in the decision-making process, and now more than ever before the option of racking style for storing your products is becoming less and less inescapable as warehousing and operations evolve. Agv's (Automated Guided Vehicles) are an example of the newest elements that have been introduced into the mix. The most tasteless types of storehouse racking available are:
1. Teardrop racking
2. Structural racking
3. Single-deep selective rack
4. Double-deep selective rack
5. Pushback
6. Drive in/Drive-through
7. Portable racking or "Stack Rack"
8. Gravity flow rack
9. Cantilever
Rack Rails
Many other options for goods storehouse exist, along with shelving, mobile shelving, and mezzanines, but for the sake of this "101" style course, we will stick to the basics. (For supplementary information on other goods storehouse options, see my old article on salvage storehouse Space - Seven Proven Strategies.) To start the process of elimination for your facility, we first must ask the right questions.
The First Step: Discovery
1. What is my product?
The type or whole of products or services that a firm offers can vary greatly. In a dedicated manufacturing environment for example, maybe no more than 3-5 Sku's (Stock holding Units) exist. However, a 3Pl (a Third Party Logistics, or ageement warehousing, provider) can have thousands of Sku's depending on any whole of factors. For example, how many customers are handled at that one facility? Or is this location dedicated to one customer? How many products of each customer's are at this location? Does the 3Pl specialize in only one type of goods storehouse and handling?
Product type is a key factor. Is the goods stored in barrels, containers, bags, pieces or cartons? Is it palletized? What are the pallet dimensions when loaded? How much does it weight? Does the goods hang over the pallet?
With so many questions, we should start by saying that, if possible, floor-stacking your product, the act of stacking on palletized goods on top of another, is the singular best recipe to use with regards to both cost and storehouse density. Floor-stacking does not want the buy of storehouse racking that takes up necessary storehouse space, development this the beloved recipe of 3Pl's in any place (much to the chagrin of pallet racking manufacturers and distributors!) The ability to floor-stack a goods is based on the stability of the loaded pallet combined with the product's capacity to cope the weight without buckling on itself. But even if it can cope the weight, floor-stacked goods should never exceed four pallets high for stability purposes.
If your firm is not a 3Pl, or if floor-stacking your goods is not possible, then you need to value exactly what it is you are finding to store. How many different Sku's do you have? How much of each Sku is there at any one time? What are the sizes of each Sku? Does 80% of your firm draw from 20% of your total Sku's? All of these answers play a role in determining your racking preference.
Also, the smart designer will plan not just for the total maximum amount, but will also add 20%-30% to that shape in order to list for hereafter firm growth. While pallet positions sitting empty for a consolidate of years waiting for the firm to grow are a waste of space, using equipment that is designed to improve with you wherever potential is always the exciting option.
2. What is my throughput and velocity?
Basically, how much goods (raw, finished, and mid-process) goes through your facility at any one time, where does your goods go within your facility and how fast is your goods exciting from receiving to shipping? Does some of it sit for a while before it ships out? Do you have a dozen or so forklifts transporting goods back and forth at any one given moment in time or does your firm have only one forklift driver? Are you a manufacturing plant using "Just In Time" processes? Does your goods expire? Do you use Fifo (first in, first out) or Lifo (last in, first out,) or neither?
3. What kind of material handling equipment do I have?
The singular best ask to ask at this point is the following: Are my forklifts going to resolve the racking I use, or is the racking I use going to resolve the forklifts I get? Where are you in the process? If you already own (and are locked into) the lift trucks you have (or are acquiring,) then you plainly have to work within the confines and limitations of that equipment.
If, however, you have the luxury of being in the enviable position of having a option of lift truck and storehouse recipe to use, then the only limitation you have is your existing budget. If you are not in a position to buy new (or even used) forklifts, then ask yourself if you wait until you are.
Understand that the material handling equipment you use is vital in this decision. Believe it or not, I once heard of a situation where the racking sales rep didn't ask about nor look at the type of forklifts that his buyer was using, and when double-deep racking was proposed, the fresh-out-of-college storehouse owner didn't think about that either. Thank God that the project never made it past the "Letter of Intent" stage, because those four-wheel sit-down forklifts would have had a hard time picking goods out of the second (two-deep) pallet position without a reach mechanism!
4. How much room do I have to work with?
The dimensions needed go beyond (length) x (width) x (height). The forklift limitations described above in ask #3 have to be taken into account, which includes the right angle stack aisle clearance width necessary for safe rack interaction. Also, take into list the placement of your other equipment (machine tools, battery charging station, containers area,) as well as your shipping and receiving areas.
Do you need to create more room? See my old article on salvage storehouse Space - Seven Proven Strategies here.
5. How much flexibility do I need?
The savvy storehouse layout planner will understand that the only constant in firm (besides taxes) is change. That includes goods sizes, volume, throughput and velocity, or even facility moves or consolidations. You need to take into list that today's goods may be tomorrow's trash. Flexibility is an absolute must when inspecting storehouse alternatives.
Questions to ask are: How fast can I modify this rack? What modification limitations do I have with this? If I need to turn storehouse equipment, how will that corollary my handling equipment (lift trucks, etc...)? How much time do I have to turn equipment over if my goods changes? What is the lead time when I order new rack?
An supplementary hint: Whenever you are finding to order anything new, regardless if it is rack, lift trucks, or office supplies, get the lead time. Always, always, always get the lead time. When you get that time frame, you then can work backwards from the longest lead time potential to get the last day you can make a decision on a project. For example, if today is July 1st, you need new storehouse rack delivered and installed by no later than September 1st, delivery lead times are 4-6 weeks out and the project will take one full week to install, then the last day for you to make a decision will be 7 weeks before September 1st, or July 14th.
If you want to factor in Murphy's Law, as the savvy storehouse layout planner will do, you will make your decision by July 7th.
The Next Step: Solutions
Now that we have our questions answered, we can now move on to which type of storehouse explication may work best. Again, there are other options available, and all options should be explored, but we will stick to the most tasteless for simplicity's sake.
1. Teardrop racking
Teardrop and Structural Racking (#2 below) are not methods of storage, they are different designs of rack, but the two varying styles do need to be covered as there are differences in capacities and cost. The teardrop design is a hole punched into roll-formed racking in the shape of an upside-down tear. The beams have a locking gismo that slides into the large hole in the frame and locks down into place. Holes are typically spaced 2" apart offering placement flexibility, and the recipe of facility will save money on the labor needed to assemble the racking.
Most teardrop style racking manufacturers also make interchangeable racking, meaning one manufacturer's racking can be used with another's. This means you're not "locked in" to any one given rack producer, which offers you flexibility later on down the line. This is also the most sought-after racking in the middle of the two, meaning should you wish to offer your rack on the used shop later on down the line, you can be assured that, more than likely, there will be a ask for it if it is in good shape.
2. Structural racking
The Structural design of racking is designed for heavy-duty applications. A stronger steel design is used and beams are bolted on to the uprights or frames instead of being slid into place. While structural steel does offer a stronger rack module with a higher capacity, it is more high-priced when compared to teardrop both in the equipment buy and in the installation. Structural racking has its place, and in some cases may be mandatory. Ask a mighty counselor for assistance in determining your needs.
3. Single-deep selective rack
This is, by far, the most tasteless storehouse explication I see, and for good reason. singular deep selective rack interacts with most if not all types of forklifts, can fit into approximately any environment, and offers the most flexibility. While it is not the most sufficient use of floor space available, it rates top in selectivity. You can always pick every pallet at any time in any place in single-deep selective rack.
4. Double-deep selective rack
Offering more storehouse density (up to 40% more than singular deep selective rack in some applications,) the only true drawback to double-deep storehouse racking is the necessity for a extra type of forklift, the reach truck. The reach truck is a specialty type of forklift that is designed primarily for rack interaction and goods staging to shipping or pallet pick-up from receiving. High throughput and velocity operations will advantage the most from this storehouse recipe as this environment usually requires dedicated forklifts such as the four-wheel sit-down lift trucks and the walkie-riders, which can cope most of the other pallet vehicle functions throughout the facility.
If you have a high ceiling, this racking also offers a larger module footprint than single-deep racking, thus development for a more garage system, and some reach trucks can now lift pallets to 37' high! extensive available square footage must be weighed against the total Sku count however since selectivity decreases.
5. Pushback
A Lifo application, pushback racking systems can typically go in any place from 2-5 pallets deep. Pallets are placed by forklift on a gravity-controlled cart within the rack. If there is goods already on a cart and space is available behind it, the forklift (pallet) pushes the cart back and the new pallet is placed on the cart in front of the primary pallet. Unloading of the pallets plainly works in reverse, with the full cart behind the picked pallet exciting send after the picked pallet is unloaded from the rack.
Selectivity decreases, but pallet storehouse density increases. Low to mid-range Sku counts work best here.
6. Drive in/Drive-through
A low Sku, high density explication that can be utilized for both Lifo (Drive-In) and Fifo (Drive-through) storehouse methods. Drive in/through modules utilize rails that act as pallet supports, and run as deep as the principles provides, eliminating aisles and thus expanding density and cube utilization. One problem with this storehouse recipe is called "Honeycombing," whereas singular slots can come to be un-utilized until pallets in front (or behind) of the slots are removed.
Where pushback racking offers more versatile storehouse than Drive in/through racking because each lane flows independently, Drive In/Thru may be have the most storehouse density in the middle of the two solutions. There is a trade-off, and a mighty counselor can offer answers.
7. Portable racking or "Stack Rack"
Applications without fixed racking design requirements, changing available racking space, volatile storehouse needs, granular goods stored in large bulk bags, or other extra products may want Portable or "stack rack." This is a great application for low to mid-range velocity and throughput applications as you are no longer confined to a specific rack design. When not in use (and depending on the design,) these racks typically stack and nest within themselves for easy storage.
8. Gravity flow rack
Flow racking is a specialty type of racking most ordinarily found in pick modules in a Fifo system, but is also found in bulk racking systems as well.
In a typical bulk rack module, pallets are loaded onto the module onto the back end, and the pallets "flow" via flow-rails to the front picking end, automatically rotating stock. This principles works best with a low to mid-range whole of Sku's (depending on available space) and is one of the densest storehouse methods available. usually the whole of forklifts and manpower can be reduced using this technique as well.
In a typical pick module system, flow racking is the lowest row of racking and the top levels are for "replenishment." Full pallets are brought down from the replenishment levels and are loaded into the rear of the system. They then flow via gravity into the front or face of the system, which is the pick area. Pickers are instructed via pick ticket (or a pick to light or other similar system) to pick off of the pallet either cartons or pieces to fulfill an order as it proceeds down the principles via conveyor.
9. Cantilever
Cantilever racking is someone else specialty type of racking. It is found in manufacturing or lumber yards primarily, but can be used in any place longer goods is stored. This can contain drywall, sheets of plywood or metal, steel bars used in processes, tubular products, or any other elongated material.
An supplementary hint: When planning your goods placement in the warehouse, use the 80/20 rule mentioned before. usually 80% of your firm comes from 20% of your product. list for that by placing the 20% of the goods closest to the shipping, processing, or picking areas. Placing the least used goods in the pallet positions that are the furthest away, then working your way in, will help you in your planning.
This information should serve as a guide and a great beginning point for anything finding to lay out a storehouse floor plan. In the upcoming weeks, I will go into each type of rack with greater information in order to aid with the intricacies of each style.
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