Design of warehouse

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DESIGN OFWAREHOUSE

Presented By- Akash GujarathiM.PharmPoona College Of Pharmacy, Pune

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TABLE OF CONTENTS Definition Warehouse site Selection & Design Layout Warehouse Management Processes Type of material Flows Types Of Storage Systems Sampling and Dispensing Booths Warehousing Operational Needs Warehouse Optimization and Simulation Good practice Warehouse Mapping References

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Definition – A designated place where goods are stored to balance demand & supply uncertainty, to serve customers in much better way, to consolidate upstream flow and distribute downstream flow as per requirement, to do last mile value addition such as packaging, kitting etc. and to reduce last mile distribution cost.

WAREHOUSE SITE SILECTION

Additional Factors

• Roads • Power • Water • Other utilities

Key Criteria (Cost vs. Service Reliability)

Cost (Warehouse Operations

and Maintenance)

Serviceability (Proximity to Customers or

Ports)

Availability of Transportation

Infrastructure

Availability of Skilled Manpower

Government RegulationsStrategic Factors –

monitoring & control, predetermined sites, future

plans

Environmental Factors4

DESIGNING LAYOUTObjective

1.Ensuring Maximum utilization of space 2. Maintaining a balance between Service and Operating Cost 3. Using the most suitable unit load4. Minimizing movement5. Planning and controlling movement and location 6. Providing Safe, Secure and Environmentally sound conditions

Designing BasicsIn case of existing warehouse • Analyzing current and projected data on the activities in each of the areas of receiving, shipping and inventory levels. • The data should be supported by other considerations such as process flows, material handling equipment, type and styles of racking equipment, special handling requirements, and personnelIn case the New Warehouse • The designing will start for the Strategy document of the Organization and then further drill down to the Need and possible benefits of the Warehouse • Once this is established only then the designing of the new Warehouse begins

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PARAMETERS TO BE PLANNED WHEN DESIGNING

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TYPICAL LAYOUT OF PHARMACEUTICAL WAREHOUSE

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WAREHOUSE MANAGEMENT PROCESSES

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OPERATIONAL PROCESS

Receiving Put-away Storage

Inbound Activities

ProcessActivities

PickingPackingShipping

Outbound Activities Process

Activities

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RECEIVING AND PUT AWAY

TYPE OF MATERIAL FLOWS U Flow

C. Low Demand Items

Quarantine Area

Empty palletes

Staging Area

A. High Demand Items

B. Medium Demand Items

Battery Charging,

etc

Order Assembly

and packaging

Expansion

ExpansionExpansion

Incoming Goods

Outgoing Goods

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Excellent utilization of dock resources because the receiving and shipping processes can share dock doors

Facilitating cross-docking because the receiving and shipping docks are adjacent to one another

Excellent lift truck utilization because put away and retrieval trips are easily combined and because the storage locations are closest to the receiving and shipping docks, they become natural locations to house fast moving items

Yields excellent security because there is a single side of the building used for entry and exit

Advantages of 'U' Flow

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Through Flow

C. Low Demand Items

A. High Demand Items

B. Medium Demand Items

B. Medium Demand Items

C. Low Demand Items

Incoming Goods Outgoing Goods

Expansion

Expansion

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The major disadvantage of a 'Through' flow layout is goods need to travel the full length of the warehouse, even for goods that are fast moving It is also harder to control and less flexible

When is it better to adopt a 'Through' flow? When there is a risk of interference or confusion

between Goods In and Goods Out When goods inwards vehicles and dispatch vehicles are very different; for example differences in platform height or nature of unit load

When the warehouse is connected to a production Plant

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TYPES OF STORAGE SYSTEMS

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TYPES OF STORAGE SYSTEMS Dedicated Storage

Product is assigned a designated slot. With multiple product storage, the space required is the sum of the max storage requirements for each of the product

Randomized Storage Product is randomly assigned a storage location close to the input/output point. The space requirement will be equal to the max of aggregate storage required for the products.

Class-Based Storage A mixed policy where products are randomly assigned within their fixed class. The classification is done based on the movement of the SKU

1. The 20% items which have 80 % Storage/Retrieval activity are termed as Class A

2. The next 30% items which have 15% Storage/Retrieval activity are termed as Class B

3. The next 50% items which have 5% Storage/Retrieval activity are termed as Class C

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TEMPERATURE CONTROLLED STORAGE AREASRequirements An external building envelope with a high standard of

thermal insulation. Tight control of air infiltration through the external

envelope. Control of heat loss and heat gain through door

openings; this can be achieved using lobbies and strip curtains.

Passive or low-energy heating and cooling systems such as ground-source heat pumps, night-time cooling or evaporative cooling.

Control of temperature stratification using a purpose designed de-stratification system that maintains even temperature distribution throughout the volume of the temperature-controlled zone

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COLD ROOMS AND FREEZER ROOMS Typically cold rooms and freezer rooms will

be constructed within the main building envelope, using pre-fabricated insulated panels. All rooms should have 100% standby capacity in the event of a refrigeration unit failure

Low temperature storage(8 to 20ºc) Cold Storage (2 to 8ºc) Refrigerated Storage (less than 2ºc)

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WALK IN COLD ROOM

For smaller rooms up to 100 m³ or so the simplest arrangement is to build walk-in rooms with adjustable shelving as the load support system.This particular arrangement includes an area in the centre of the room for the temporary storage of campaign vaccines and other overspill products.

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PALLET RACKING COLD ROOM WITH TEMPERATURE-CONTROLLED PACKING AREA

If sufficient height is available to install pallet racking, a high rise cold room is likely to be the most space and volume-efficient arrangement for a larger pallet store.

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PAKAGING MATERIALS STORE Packaging materials are stored and

separated according to their category ,i.e. Primary packaging materials Printed packaging materials Other packaging materials

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SAMPLING & DISPENSING BOOTHS Following points should be

considered at the time of designing.

Two booth Reverse Laminar Air Flow

unit An additional exit (floor

level batch) may be planned from the backside of the dispensing booth to dispatch the dispensed goods to production.

A separate room for cleaning & drying the sampling & dispensing utensils.

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WAREHOUSING OPERATIONAL NEEDS

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AUTOMATION IN WAREHOUSES- PUROSE

• Productivity - Increase in Production- Modernization of existing

system- New line set up- Line flexibility to handle

various sizes• Quality

- Final inspection on 100% products

- Stage inspection• Safety

- Handling of Hot products- Handling of Hazardous

products- Continuous handling of heavy

objects

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A stacker crane is the automatic machine installed inside rack to serve storage and retrieval operation. It critically influences AS/RS performance developed with know how achieving low-price, high speed, light- weight & stabilization.

Sorter system sorts individual materials to a designated place according to its own information specified by the bar-code or RFID attached to them by automatically distributing and collecting with the conveyor and sorter.

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Digital Picking System Gantry

ROBOT PALLETIZER

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WAREHOUSE OPTIMIZATION AND SIMULATION

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GOOD PRACTICE WAREHOUSE MAPPING

1.Create a validation plan 2. Identify areas at risk 3. Develop protocol information 4. Determine sensor distribution 5. Select suitable technology 6. Set up mapping equipment 7. Conduct test and review data 8. Make modifications 9. Document and schedule mapping tests

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REFERENCES Design and procurement of storage facilities

Technical supplement to WHO Technical Report Series, No. 961, 2011

Prof. Potdar M.A.-“Pharmaceutical Facilities: Designs, Layouts And Validation”

An Introduction to Warehousing-o-links Supply Chain Simplified

GMP Warehouse Mapping / Step-by-Step GuidelineS for ValidatinG life Science Storage facilities

Receiving And Put Away www.youtube.com/watch?v=ZN6--Xi5lKo

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Thank You

The Quality Of Your Work, in the Long Run, is the deciding factor on how much Your Services are valued by the WORLD

-Orison Swett marden