Warehouse Design & Layout

- Perancangan Fasilitas pada Warehouse-

Oleh :
Debrina Puspita Andriani, ST., M.Eng
Teknik Industri, Universitas Brawijaya
10
e-mail : debrina@ub.ac.id
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Mission of A Warehouse 2
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•  PERSEDIAAN
! penyeimbang dan
penyangga akibat adanya
perbedaan antara perencanaan
produksi dengan permintaan
aktual
•  KONSOLIDASI BARANG
! penggabungan barang-
barang dari beberapa pabrik
atau gudang kecil sebelum
dikirimkan
•  DEPO
!Gudang penyangga yang
mendekati pasar, untuk
mempercepat respon supply

Jaringan Distribusi dan Warehouse 3

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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)

Main Functions in the Warehouse 4

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RECEIVING & SHIPPING
OPERATIONS 5
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 Replenishment Replenishment
Broken Case
Case Picking
Reserve storage and Picking
pallet picking

Accumulation sortation packing and

Direct put away

utilization
to reserve

Receiving Cross-docking Shipping

Typical warehouse functions and flows 6

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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) 7

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The Flow of 2.  Transportation facilities on two
Material
adjacent sides of building

R S R S

Receiving & Shipping Operations (2) 8

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The Flow of
Material
3.  Transportation facilities on two
opposite sides of building

Highway or Railroad

R R R

S S S

Receiving & Shipping Operations (3) 9

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 2 3
1 Determine the space
Determine the
Determine what is to be requirements for the
number and type receiving and shipping
received and shipped
of docks area within the facility

Receiving & Shipping

Space Planning 10
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 1. Determine what is to be received and shipped

Receiving & Shipping Analysis Chart

Company( Date( Raw(Materials( Finished(Goods(

Prepared(by( Sheet( of( Plant(Supplies(

1( 2( 3( 4( 5( 6( 7( 8( 9( 10( 11(
Unit(Loads( Size(of( TransportaGon( Material(Handling(
Frequency(
DescripGon( Shipment(
Type( Capacity( Size( Weight( of(Shipment( Mode( SpecificaGons( Method( Time(
(unit(loads)(
(( (( (( (( (( (( (( (( (( (( ((
(( (( (( (( (( (( (( (( (( (( ((
(( (( (( (( (( (( (( (( (( (( ((
(( (( (( (( (( (( (( (( (( (( ((
(( (( (( (( (( (( (( (( (( (( ((
(( (( (( (( (( (( (( (( (( (( ((
(( (( (( (( (( (( (( (( (( (( ((
(( (( (( (( (( (( (( (( (( (( ((
(( (( (( (( (( (( (( (( (( (( ((

Receiving & Shipping Space Planning 11

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 2. Determine the number and type of docks

The number Rail docks

of docks
Truck
docks
Determine the
Waiting line time required to Type of Drive in
analysis load or unload a
carrier
Docks docks

Poisson Time study :

900 docks
distribution or work sampling,
Simulation PMTS, etc. Finger
docks

Receiving & Shipping Space Planning 12

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for R/S Area
Minimum Maneuver Jenis Alat Material Handling
Minimum Maneuvering
Allowances (ft)
Tractor 14
Platform truck 12
Forklift 12
Narrow aisle truck 10
Hand-lift (jack) 8
Four-wheel hand truck 8
Two-wheel hand truck 6
Manual 5

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 3. Determine internal receiving and
shipping area requirements

Trash disposal & recycling Pallet and packaging material

Personnel convenience/offices A receiving hold area
bins storage/palletizing equipment

Material handling equipment

The truckers’ lounge Buffer or staging area
maneuvering

Receiving & Shipping Space Planning 14

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DOCK LOCATIONS 15
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Lokasi dan Layout Dock 16
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 Dock Levelers Bumper Pads Dock Shelters

As the interface As the interface As the interface

between a dock at between a fixed between a heated/
a given height and dock and a air conditioner
variable-height moveable carrier dock and an
carriers unheated/non-air-
conditioned carrier

Dock operations planning 17

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 1 2

Material flows
3 Expansion directions
(Receiving and shipping
activities)

Modular design of storage/warehouse

facilities with expansion alternatives 18
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STORAGE OPERATIONS 19
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•  Stacking Frames
•  Cantilever Racks
•  Selective Rack
•  Flow Rack
•  Racks for Automated Storage and Retrieval System (AS/
RS)

Storage Medium 20
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Stacking Frames 21
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Cantilever Racks

22
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Selective Rack 23
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Flow rack 24
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AS/RS (Automated Storage / Retrieval
Systems) 25
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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 26
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•  Penentuan lokasi gudang yang didirikan
merupakan permasalahan awal dan kritis
dalam perancangan gudang.
•  Permasalahan berikutnya adalah berapa
unit gudang yang harus dibangun serta
luas dari tiap unit gudang tersebut.
•  Faktor yang harus dipertimbangkan dalam
pembangunan gudang antara lain:
•  Lokasi Pelanggan/Pengguna,
•  Tingkat layanan yang diharapkan kepada
pelanggan,
•  Harga tanah, biaya sewa, pajak, biaya
konstruksi, dan asuransi.

Lokasi Gudang 27
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 Storage
Tinggi
media yang
bangunan
digunakan

Luas lahan
S/R methods
yang tersedia

Layout
gudang Jalan/lintasan
Barang yang
disimpan tergantung pada rak
beberapa hal, penyimpanan
yaitu:

Layout Gudang Secara Umum 28

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Layout Of
Warehouse
Store

29
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 Prinsip yang diperhitungkan dalam perencanaan gudang:

Popularity Similarity
Utilisasi
Frekuensi Item yang Size
ruang
perpindahan diterima pengelompo Characteristics
termasuk
barang, dan dikirim kan Jenis dan sifat
luas lantai
masuk bersamaan, berdasakan barang yang
storage
(receiving) seharusnya ukuran fisik disimpan
kemudahan
dan keluar disimpan barang
akses
(shipping) bersama

Storage Layout Planning 30

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 Randomized Dedicated storage Cube-per-order
storage policy policy index (COI) policy

Class-based storage Shared storage

policy policy

Storage Policies 31
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 •  Dirancangan berdasarkan hukum
Pareto:
“80% the turnover will be as the result
MEDIUM MOVING
of 20% of material stored”.
SLOW MOVING

FAST MOVING

Entrance/Exit
•  Sehingga 20% material yang
ITEMS

menentukan tersebut dipertimbangkan

ITEMS
ITEMS

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 32
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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$120$
80%
110$100$ 90$ 80$ 70$ 60$ 50$ 40$ 30$ 20$ 20$ 30$ 40$ 50$ 60$ 70$ 80$ 90$ 100$110$

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 33

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Barang mudah busuk/tidak tahan
lama, seperti ikan, sayur, buah, dll.
Media penyimpanan dirancang dengan
temperatur yang khusus.
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 berbahaya/beracun, seperti

Barang berharga/kecil. Penanganan
cat, pernis, bahan kimia yang mudah
barang yang mudah dicuri dan
meledak, dll. Penanganan khusus
bernilai tinggi harus
terhadap barang ini diatur dalam
mempertimbangkan penjagaan dan
regulasi safety dan harus menempati
lokasi penempatan yang aman.
lokasi yang aman dan terisolir.

Rencana Barang yang bersesuaian. Barang yang akan

Penyimpanan rusak jika ditempatkan berdekatan dengan barang
yang mempengaruhinya secara kimia /fisik.
Berdasarkan Seperti margarin, jika disimpan diruang
Karekteristik pendingin bersamaan dengan ikan, maka bau
ikan akan mempengaruhi/merusak aroma
Barang margarin. 34
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ORDER PICKING
OPERATIONS 35
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Work$Element$ Method$of$Elimina<on$ Equipment$Required$
StockUtoUpicker(System(
Order
Traveling$ U(Miniload(AS/RS(
Bring(pick(locaGons(to(picker( U(Horizontal(Carousel(
Picking
(( U(VerGcal(Carousel( Work
Documen<ng$
Computer(Aided(Order(Picking(
Automate(informaGon(flow( AutomaGc(IdenGficaGon(System(
Elements &
(( LightUAided(Order(Picking(
VerGcal(Carousel(
Means for
Reaching$ Present(items(at(waist(level( PersonUaboard(ASRS(
(( Miniload(ASRS(
Elimination
Sor<ng$ Assign(one(picker(per(order(
and(one(order(per(tour( ((
Bring(pick(locaGon(to(picker( StockUtoUpicker(System(
Searching$ Take(picker(to(pick(locaGon( PersonUaboard(ASRS(
Illuminate(pick(locaGon( PickUtoULight(System(
Extrac<ng$ AutomaGc(Item(Pickers(
Automated(dispensing( RoboGc(Order(Pickers(
Weigh(count( Scales(on(Picking(Vehicles(
Coun<ng$ Prepackage(in(issue(
increments( 36
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 Pickers(Per( Line(Items(Per( Period(Per(
Procedure(
Orders( Pick( Shi](
Discrete( Single( Single( Single(
Zone( MulGple( Single( Single(
Batch( Single( MulGple( Single(
Wave( Single( Single( MulGple(
ZoneUBatch( MulGple( MulGple( Single(
ZoneUWave( MulGple( Single( MulGple(
ZoneUBatchUWave( MulGple( MulGple( MulGple(

Methods of Order Picking 37

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•  Tompkins, White, Bozer and Tanchoco. (2010). Facilities
Planning (4th Ed.). New York: Wiley.

REFERENCES 38
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•  Satu kelompok
•  Identifikasi dan analisis
= 7 orang
•  Urut Presensi
•  Dikumpulkan dalam
softcopy pada minggu
depan
•  Referensi : Tompkins,
White, Bozer and
Tanchoco. (2010).
Facilities Planning (4th
Ed.). New York: Wiley.
Tugas
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FACILITIES SYSTEM pada
suatu perusahaan yang
meliputi:
•  Structural Systems Performance
•  Enclosure Systems
•  Atmospheric Systems
•  Lighting and Electrical Systems
•  Life Safety Systems
•  Sanitation Systems
•  Building Automation Systems
•  Facilities Maintenance Management
Systems
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