Reception Process

Autor: Joselyn Yagual Reyes

Warehouse Management
Steps of reception process
Product reception is the process by which a product (or set of products) from the supply source
(supplier, factory) reaches the warehouse to be classified, controlled, and entered in the WMS
(Management System of Warehouse) for subsequent location within the installations of
warehouse and be ready to be sent to the customer or final consumer according to shipping
requirements.
They can come in different formats (single-reference pallet, multi-reference pallet, box, etc.)
according to size, type of product, origin, etc., this format being a key factor in the process of
handling and classifying them.
The reception process is divided into the following three phases:
(I) External visual check
Three simple steps that will ensure that the receipt of the merchandise is done faithfully and
effectively:
1. We will proceed with the unloading of the product if it comes in transport with
mechanical means or we will receive from the carrier if it is a small package.
2. We will verify in the delivery document that; indeed, we are the recipient and that the
number of packages delivered to us matches what is indicated.
3. We will check that the merchandise received is in good packaging condition and that it
does not show signs of tampering (broken seals, open or broken boxes, dampness, etc.),
always bearing in mind that the packaging plays an important role in protecting the
material. It is very important to indicate any anomaly in this regard in the delivery
document that we seal / sign to the carrier because it is the only way to claim in case of
missing or hidden breakages.
4. If we are not going to make the entry of the merchandise immediately after its
reception, we will place it without unpacking in an area that we will designate for this
purpose, that we will not use for another purpose and that will be inviolable, that is,
nothing must leave this area without having had its corresponding entry treatment in the
warehouse to form part of the existing stock. Nor will we put in this area, goods that are
already in our stock or that are part of an outbound shipment, this will make our
warehouse a reliable stock place on which to base ourselves to carry out the necessary
outputs.
(II) Verification documentation
To enter the merchandise in our stock and in the circuit, we will follow the following steps in an
orderly manner:
1. We will create an entry document based on the purchase order that we made to our
supplier, so that we can link it with the delivery note (or packing list) when the
merchandise arrives. We will check this document with the merchandise delivery note,
and we will verify that the references and quantities coincide with what was requested.
2. We will make the appropriate modifications in the entry document with the possible
surpluses and missing, creating an attached document if we want to return to the
supplier any of the materials received and not requested or if the quantities indicated in
the delivery note with what was received.
Reception Process
Autor: Joselyn Yagual Reyes

3. With this document it will be the one with which we will count the received
merchandise, marking references, quantities, expiration dates and any other information
that is necessary in the registry and not with the delivery note because, in this way, we
will filter the possible transcription errors that may occur when entering the material
once counted and that would provide wrong data to our stock.
(III) Internal product check
When we receive the entry document and proceed to the check, we will act as follows:
1. We will unpack the material taking special care not to damage the merchandise with
cutting tools and we will keep the residue until the end of the process; It often happens
that small pieces go to the waste container because they are hidden among the
protective material, and we realize their lack when the packaging has already been
discarded.
2. We will separate the different materials to identify them and classify them according to
their size, shape, quantity, or any other criterion that we consider operational and once
separated, we will check, one by one, that all the merchandise received coincide in
reference and quantity, noting in the document of input the differences that we find.
3. We will identify the merchandise with our registry to be able to locate it in our
warehouse so that it is located quickly and easily. Once the complete check of the
merchandise has been carried out, we will proceed to its location, which will be
registered in our warehouse, manually or with radio frequency if this system is
available. It is important not to locate anything until all the merchandise is checked, so
we will have more facility to locate identification errors and correct them at the time
since if we misidentify any reference and we have already located it, we can hardly
check if it is our error when checking or the supplier when sending the material, unless
we return to the location to check all the references transferred each time the case is
presented to us.
4. We will return the entry document duly completed with the required data and with
possible discrepancies to our administration so that it can make the appropriate
modifications, modify the quantities that we are going to receive and notify the supplier
of the shortages or to remove the surpluses.
Once this process is finished, the excess quantities will remain in the reception area until they
are treated. This treatment will consist of giving us an entry document for the remaining
quantities so that we can identify and locate it, or a return document that we will attach to the
merchandise that we are not going to incorporate into the warehouse and that we will leave in an
area designated for that purpose. well identified, packaged and accessible for when the supplier
picks it up.
It is time to remove the packaging remains to leave the reception area always in the best
operating conditions.
An effective reception provides us with ease and speed in the preparation of orders and brings
fidelity to our inventory.
Reception Process
Autor: Joselyn Yagual Reyes

Considerations regarding different types of products, docks

characteristics

The dock area is a vital hub of activity in many facilities, whether it is a factory, warehouse,
plant, or other commercial space. Inefficient loading dock design, processes, and equipment can
be very costly for the company. Proper dock design can improve essential loading dock area
functions and enhance worker safety.

The most common types of loading docks include the following:

Enclosed Loading Dock

Enclosed docks are generally used when product protection, climate control, security
and overhead lift capabilities are needed. This type of design is frequently used by
package handlers with box truck fleets since it improves efficiency and comfort while
decreasing the chance of theft.  This design also allows s space for overhead cranes that
will efficiently load and unload flat-bed trucks.

An enclosed dock is also the most expensive loading dock design since it requires initial
investment and maintenance. Safety concerns for this type of dock include the need for
proper ventilation and air-exchange because of truck exhaust fumes that occur inside the
building.

Flush Loading Dock

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Autor: Joselyn Yagual Reyes

Flush docks are the most common type of loading dock. This type of dock is flush with
the outside wall of the building and has the same foundation as the wall. 

Some safety considerations for flush docks include ensuring that building wall goes past
the foundation (due to the use of metal or other materials) and dock bumper protection.
With this type of dock, bumpers should have a minimum of 4.5” feet from the wall, and
the wall should project at least one foot past the foundation where the bumpers are
mounted.

Open Loading Dock

Open docks are not usually recommended or used due to exposure to outside weather
and the possibility of making it easier for theft to occur. Open loading docks often
cannot be heated or cooled efficiently, and they do not provide adequate protection for
product, materials, or workers. Proper floor drainage is also a consideration due to
weather exposure. Edge markings, run-off protection, and handrails may be required as
per OSHA standards for an open loading dock.

Open loading docks should always have a canopy. If the canopies are planned over
docks that are on sloped grades, the canopy height must be calculated to accommodate
trailer height.

Sawtooth Loading Dock

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Autor: Joselyn Yagual Reyes

Sawtooth docks present a solution to design situations where the apron space is limited. 
Sawtooth line-ups are used when there is limited space to maneuver vehicles. However,
the oncoming roads should be designed in a way that trailers and trucks leave in the
direction of the angle of the dock. The trucks will require less space to move around
because they are already lined up in the direction of the driveway.

However, sawtooth loading docks reduce the use of dock space, which makes it more
difficult to move and store incoming product, because the staging area between docks is
typically not useable.

Declining or Inclining Loading Dock

When the building or facility does have basements or dock-level floors, then declining
loading docks with slope driveways are often used. Incoming trucks are backed into
position at an angle determined by the percentage of the decline of the driveway.

When designing a declining loading dock, the grade of the driveway should not exceed
10%.  This design prevents the top of the truck from hitting the ceiling of the building,
stops loads of cargo from toppling out, and eliminates traction problems due to snowy
or icy conditions.

Another method of design for a decline loading dock is to move the dock leveler pit
forward. The amount of projection is determined by the grade of the driveway decline.
Projecting the dock leveler pit at the onset can reduce damage caused by vehicle impact
to the building, as well as the need for bumper extensions or longer hinged lip
assemblies. You will find the same is true on an incline as well.  Except, instead of the
top of the truck, it’s the bottom of the ICC (aka Jane Mansfield) bar that could hit and
damage the face of the loading dock.

If the decline or incline of a loading dock is severe, cargo may fall out, unloading and
loading boxes can be tricky, and higher wear and tear will be placed on any equipment
that is used for product handling.
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Autor: Joselyn Yagual Reyes

Different storage techniques

Storage techniques can be divided into the following types:

 Floor storage
 Static rack storage
 Dynamic rack storage
 Storage on conveyors
 Special case channel rack warehouse

Storage techniques – floor storage

In floor storage, the goods are stored without fixed devices, such as shelves, mounted in
the warehouse.
Floor storage is to be divided into three basic types:
1. Unstacked warehouse
2. Block storage
3. Row storage

Unstacked warehouse
In the case of unstacked storage, the loading units are stored next to each other. An
unstacked warehouse consumes a lot of space and is, therefore, less suitable for use
inside closed buildings. It is mostly found in open warehouses with a small number of
different articles.
Block storage
In block storage, the loading units are stored without fixed devices, such as shelves. The
goods are usually stacked in several layers on top of each other and next to each other.
The goods, for example in boxes or on pallets, are usually stacked in several layers on
top of each other and next to each other. The use of a block warehouse is suitable for
goods of the same type, rarely required goods and high withdrawal quantities.
In the case of stable, non-pressure-sensitive goods, simple pallets without their own
devices are sufficient for block storage. In the case of unstable goods, box pallets or
crates are suitable.
Row storage
With row storage, storage is basically the same as with block storage, but there is free
space between individual blocks. This means that the goods can be accessed without
having to transfer units.
In the floor row warehouse, the loading units are stored in rows, with the corresponding
free spaces between the individual blocks. In contrast to block storage, this makes it
easier to access individual loading units.
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Autor: Joselyn Yagual Reyes

Storage techniques – Static rack storage

In contrast to block and row storage, static rack storage uses fixed racks. Loading units
are stored single-deep or multiple-deep on it and only moved again during the retrieval
process.

Static rack storage is to be divided into seven basic types:

1. Shelf storage with single-deep occupancy
2. Drive-in and drive-through shelving warehouse
3. satellite rack storage
4. shelving storage
5. drawer rack storage
6. cantilever rack storage
7. honeycomb racking warehouse
Shelf storage with single-deep occupancy
One design of the single-deep rack storage system is the standard pallet rack storage
system. The storage racks of the warehouse consist of fixed field widths between the
supports. The bays offer space for one or more pallets, whereby the storage of the
loading units takes place single-deep.
The standard field widths of 2.70 m or 3.60 m are matched to the dimensions of
the Europool pallet(800 mm × 1200 mm) or the German industrial pallet (1000 mm ×
1200 mm). The composition of the shelf structure is usually steel or aluminium profiles.
Single-rack warehouses can reach a height of up to forty metres (high-bay warehouse);
each loading unit can be accessed directly.
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Autor: Joselyn Yagual Reyes

Drive-in and drive-through shelving warehouse

The drive-in or drive-through shelving system is a support construction made of profile
elements. For storage and retrieval, the floor conveyor can retract or pass through.
While the LIFO (last in, first out) principle is used for retrieval from drive-in racking,
the sequence of retrieval from drive-through racking can vary. The storage sequence is
the same for both rack storage systems.

Continuous cross beams connect the vertical supports and are used to place loading
units on them. The cross beams are filled from the rear to the front of the drive-in and
drive-through racking. The load must be lifted to the level of the shelving level before
retraction. While stock placement begins at the top level and ends at the bottom level,
stock removal takes place in reverse order. This means that the first loading unit is filled
in at the very back of the top level, the second at the level below and likewise at the
very back. If the lowest level is reached, the storage is continued at the highest level.
One speaks of drive-in racks when the rack can only be accessed from one side. The
drive-in racks are closed at the end by stabilizing cross struts. A storage depth of eight
loading units per storage compartment is considered reasonable. The drive-through
rack can be accessed from both sides. Steel superstructures above the top-level stabilize
the column construction.
Satellite rack storage
The satellite rack warehouse has storage channels in which the loading units are stored
at multiple depths. The removal from storage takes place according to the LIFO
principle. The storage channels are accessed with a rail-guided rack conveyor. It is
firmly anchored in its camp lane. Instead of a telescopic fork, a so-called satellite is
installed in the storage and retrieval vehicle. The satellite vehicle is an autonomous
vehicle with a shallow overall height.
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Autor: Joselyn Yagual Reyes

Once the x/z coordinate of the storage compartment has been reached, the vehicle
disengages from the racking conveyor and enters the racking compartment. It is
equipped with a lifting device and can load and unload the loading units independently.
The cross beams of the rack storage system have two horizontal surfaces: The upper
surface is the support surface for the loading unit, and the lower surface is used as the
running surface for the satellite vehicle.
Shelving storage
Shelf racking systems are used for the storage of non-palletized loading units. This
storage type is preferably used for picking small parts. The stored goods are arranged
next to each other in containers of different sizes. All stock items can be accessed
directly. Fixed or movable partitions are used to divide the shelves.

The dimensioning of the shelving depends on the following aspects:

 Quantity to be stored per storage compartment
 Turnover frequency per article
 Assortment width
 Room availability
 Dimension of bearing unit
Shelf storage systems are usually operated manually with a maximum shelf height of 2
meters. For ergonomic reasons, the compartments in the upper and lower rows of
compartments should not be filled with A articles (fast-moving items), as the gripping
positions are very unfavorable. For higher shelves, mobile ladders or stacker cranes are
used. To make better use of the floor space, shelving systems are often built with
several stores. Gratings have been inserted between the floors, on which the warehouse
personnel can move.
Drawer rack storage
The drawer rack warehouse is used to achieve clear and space-saving storage. Loading
units are stored in drawers. The construction resembles a conventional drawer cabinet.
The use often takes place in combination with a shelf rack.
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Autor: Joselyn Yagual Reyes

Cantilever rack storage

The cantilever racking is suitable for the proper storage of long goods, such as bar stock
and plate stacks. It is preferably used in the iron or wood processing industry. The
storage rack consists of vertically arranged center supports with vertical feet. The
cantilevers are lateral outriggers on which the stored goods are placed. The length of the
cantilevers and the distance between the center supports depends on the load to be
supported. The cantilevers are attached to the center supports by means of welded,
bolted or hook connections. Whether, for example, extendable telescopes or cantilevers
with roll-off protection for bar material are used depends on the area of application.
Storage and retrieval take place transversely to the rack and usually manually with a
crane or forklift.
Honeycomb racking warehouse
The honeycomb rack is exclusively suitable for the storage of long goods. Many designs
require the use of long pallets or cassettes to fix the bar material. On the front side, the
containers are pushed into shelves, which means that the front view of the shelf wall
resembles a honeycomb. The long goods cassettes of storage and retrieval vehicles are
stored and retrieved by special load handling devices. In order to be able to push the
heavy long goods cassettes into the compartment with low friction, the shelves are often
equipped with roller conveyors or similar.

Storage techniques – Dynamic rack storage

Storage equipment is dynamic if the loading units are moved on the rack after storage.
A distinction is made between the movement of loading units on fixed shelves, the
movement of loading units with moving shelves and the movement of loading units
with conveyors.
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Autor: Joselyn Yagual Reyes

Dynamic rack storage can be divided into six basic types:

1. Flow rack storage
2. Compact shelving warehouse
3. Mobile rack storage
4. Push-in rack warehouse
5. Carousel storage
6. Rotary Rack
Flow rack storage
In the flow rack warehouse, a continuous movement of the stored goods from the
storage side to the retrieval side takes place in a rack channel. The shelf channels are
arranged in blocks. Only one article type is stored per shelf channel.
The load units are moved either by the gravitational force acting on the frame or by
external influences such as a driven roller conveyor. In the case of movement by
gravity, the trajectory is inclined by two to eight degrees. The inclination of the track
can be readjusted at any time by means of plug-in connections. This is necessary when
the loading units on the rail no longer move by themselves. To facilitating access, the
track of a container flow rack storage system is inclined so far that the foremost loading
unit is at an angle of up to thirty degrees to the loading unit behind it. The channel
length should not exceed twenty meters.
Pallet flow rack warehouses, on the other hand, are loaded and unloaded with the help
of forklifts. Access is relatively easy by adjusting the angle of inclination of the fork
according to the inclination of the shelf channel. The canal is usually up to forty meters
long.
Compact shelving warehouse
A compact rack storage system is highly dynamic and usually consists of many
autonomous units. Loading units are stored on roller pallets and these are connected by
couplings. Several units are joined together in this way.
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Transfer trolleys, so-called pallet trolleys, are used for storage and retrieval or coupling
and uncoupling pallets. By coupling a trolley, the attached pallets are also moved when
the foremost pallet is pulled. Lifting and lowering stations serve as transport vehicles on
a vertical level. Buffer spaces are used to sort loading units so that they can be made
available subsequently as quickly as possible.
Mobile rack storage
With mobile racking systems, the loading units are stored in rows. The storage racks are
mounted on undercarriages, which in turn are on guide rails. This allows the shelves to
be moved horizontally on the rails.
The individually driven undercarriages usually accommodate a double shelf, i.e., two
rows of shelves. Double shelves are usually placed adjacent to each other. Before a
specific storage compartment can be accessed, adjacent rack rows must be moved, and
an aisle formed. Only when the space between the lines is wide enough can the hoisting
equipment enter the aisle. Depending on the particular requirements, a mobile racking
system can be used, for example, for pallet or cantilever racking.

Push-in rack warehouse

The push-in shelving system consists of several double shelves arranged one behind the
other. Its design corresponds to that of a flow rack warehouse. However, the goods are
stored and retrieved from the same side in the push-in rack warehouse.
To be able to remove goods from the individual compartments, rollers are attached to
the underside of the shelves. This allows each shelf to be pulled out individually. If
large containers or pallets are to be stored in the push-in rack, they are removed by
means of floor conveyors. In this case, there are no rollers on the shelf. In the case of
light-duty shelving units, the guide is provided by guide rails.
Carousel storage
Carousel storage systems are dynamic racking systems in which the storage units are
moved by a rotational movement of the entire storage rack.
The picking principle “goods-to-man” applies, i.e. the picker is at a workstation and the
storage rack rotates until the desired storage compartment is ready. While the operator
removes goods from a shelf, the next position to be controlled can already be searched
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Autor: Joselyn Yagual Reyes

for in the adjacent shelf. Short access times can be achieved by controlling shelf
circulation by means of an optimized compartment preselection.
Depending on the direction of rotation, two rack types can be distinguished:
Carousel warehouse
Paternoster rack storage
With the carousel storage system, the storage rack is moved horizontally. Here nacelles
are suspended in driven chains. These gondolas are in turn divided into individual
storage compartments.
With the paternoster rack storage system, the storage rack is moved vertically. It is
mostly used for the storage of small parts.

Rotary Rack
A Rotary Rack is a sorting accumulator for small containers. It is highly dynamic and
combines the principles of the two storage types “carousel” and “paternoster” of the
carousel warehouse.
The containers are stored on several levels, one above the other. Each of these planes
rotates one axis independently of the other. A vertically rotating paternoster is
connected to this horizontal principle. In each storage and retrieval cycle, there are
movements of the paternoster and at least one plane.

Storage techniques – Storage on conveyors

In conveyor technology, the term “conveying equipment” refers to equipment and aids
used. Auxiliary materials can be, for example, cartons, crates, pallets and lattice boxes.
The storage of goods directly on the conveyor system is used when the functions
‘convey’ and ‘store’ are to be combined. The integration of these basic logistical
functions is aimed at, for example, in parcel sorting systems. Classic warehouses
use continuous conveyors and discontinuous conveyors mainly for transporting goods.
For storage on conveyors, there is the possibility of storage on continuous
conveyors and storage on discontinuous conveyors.
Storage on continuous conveyors includes, for example:
 Roller conveyor
 Belt conveyors
 Circulating conveyor (e.g., paternoster)
 Chain conveyors
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Autor: Joselyn Yagual Reyes

Storage on discontinuous conveyors, for example, includes:

 Motor vehicles (e.g., forklifts)
 Electric monorail conveyor
 Automatic vehicles
 Storage and retrieval machines
 Storage of hanging goods
Hanging goods are goods that may only be transported or stored hanging, such as
textiles or certain foodstuffs. These special goods may only be stored in such a way as
to avoid damage or loss of quality.

Storage of hanging goods

The simplest solution: The warehouse does not consist of storage spaces for pallets and
packages, but offers static suspended shelves. If only storage space is available in the
warehouse, the goods are hung in trolleys. Trolleys are defined as loading units, similar
to a pallet. They usually consist of a high trolley on rollers in which the goods can be
suspended by means of one or more rods. A trolley has a certain loading capacity and
can then be stored according to the usual methods. Each trolley should contain one type
of goods (for example, the same article in the same size) so that you do not have to
search for different goods within the actual storage unit. This saves time, is less prone to
errors and provides a better overview of the storage capacities still available. The
trolleys are then booked into a fixed storage location.
Automated storage of hanging goods
The methods of properly storing hanging garments described above usually refer to
companies whose warehouses are not exclusively geared to hanging garments or who
did not want to make major alterations to their previous storage facilities. If a
warehouse is specially designed for hanging goods, an automated high-bay warehouse is
often used. The goods hang on mobile storage rods, which can then be fully
automatically coordinated to the respective storage locations or transfer stations. A pure
high-bay warehouse for hanging goods has significantly lower investment and
personnel costs than a classic high-bay warehouse with storage locations.

Special case channel rack warehouse

A channel rack storage system consists of several flow paths or push-in channels, which
are arranged next to each other and one above the other in a similar way to honeycombs.
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Depending on the nature of the stored goods and the frequency of use, different storage
techniques are suitable. A distinction is made between the movement of loading units
with conveyors, the movement of loading units on fixed shelves and the movement of
loading units with moving shelves. The loading units of the channel rack storage can be
moved in the channel. In push-in channels, the loading units are stored and retrieved
from one side. With flow channels, on the other hand, the units are stored and retrieved
from opposite directions.
An active flow rack warehouse with roller conveyors or also a compact rack
warehouse are examples of a channel rack warehouse. If storage is planned for a longer
period, channel rack warehouses are generally less suitable. One possibility, however,
would be a compact warehouse with satellite vehicles. If the warehouse is intended
more as a short-term buffer and for transport provision and there are also high article
stocks, then the use of a flow rack warehouse is suitable.

REFERENCE
Storage techniques in intralogistics - Logistik KNOWHOW
Operaciones del almacén: recepción de producto - MeetLogistics
Different Types of Loading Docks (partsbrite.com)