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0530-LP-529-0000

M WarehouseModernization
and
Layout Planning Guide

Applicable to functional concepr planning for new

facilities or mod€rni2ation of exisiing faciliti€s.
Describes basic storage and material handling state
ot the art system concepts.
Provides modular layouts. system seleciion_design
crireria and comparative costs for self help analysis of
storage activities.
Provides rechniques for lacility, inventorY, product and
transaction dara analysis to be used in developang
p.eliminary alternarive tunctionai designs.
Furnishes guidance lor developing budg€tary costs and
final studies tor which erternal assistance may be

Department of the Navy

N a v a l S u p p l y S y s t e m sC o m m a n d
NAVSUP Publication 529
March 1985
 Pase No.

Integration of Storage end Support Areas

t7,r Genera 1 r7- I

17.2 Uater ia1 Flow t7- 4
hternal Arrangerieot
rt.4 Layout Techniques I7_IO

PAR? III - SUPPORTINGINFOR ATION AND SAI'IPLEPROBLEM

lntroduc t ion III- i

Section l8 Data Derivation and Standard Assumptions

I8. I 18- 1
1 8 .2 Ana lys is Procedure ta- 2
1 8 ,3 Eleoents of Analysis t8- 2
18.4 l,lodular Layouts L8- 5
1 8 .5 B u 1 1 di n g C o 6E 18 5
18.6 r8- 9
18.7 Storage Equipment Cost l8-r3
r8.8 l'|ter ial s ltandling Eq!ipnen. cost t8-18
18.9 Cost Equat ions t8-t8
t8.10 T r a n $ a ct i o n / I n v e n t o r y ( T / I ) R a r i o L8-18
18.1l P a I l e t S y st e n s t 8-26
18.i2 B i n n a bI e s o r d e r P i c k i n s S y s t e m s t8-29
t8.l3 R a c k a bl e s O r d e r P i c k i n g S y s c e n s t8 36

Section l9 Dev iat ions frofl Standards

19.I I9- I
)9.2 B ui l d i n a C o s t V a r i a t i o n s l9- 3
t9. 3 Pallet Rack and Shelving Cost Varla t lon s 19-
r9.4 Vehicle Cost Var iat ions I9-
1 9 .5 L a b o r C o st v s r i s t i o n s for PalLet Sysceins l9- 5
I9 .6 Labor Co6t var iat ion$ for
Order Pi ck in8 Systens l9-
1 9. 1 Labor cost Variations for
order Picking Systens l9 7
19.8 Fire Protec t ion I9- 7
E n v i r o n n e n c aI C o n t r o 1 s t9- 8

S e ct i o n 2 0 Il1us trat iv€ Design Probten

20.I D ef i n i t i o n o f P r o b l e n 20- l
2 0. 2 SeSmentation of Operarions 20- 4
2 0. 3 Covered Dry Storage 20- 6
20.4 Order Picking 20- 9
20.5 Support Functions 20- t2
2 0. 6 Shipping and Receiving 20-r2
20.7 P r e s e r v a ti o n , P a c k a g i n g , P a c k i n g , C r a t i n g 20-12
20.8 Preliminary Bui lding uodule Layout 20-13
20.9 Refined Bui lding Layout 20-13
 NON STACKAELT SHAPE

NON STACKABL E NE5 TABLE

S T R E N G T HO R O AMAGE

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STACKABL L I M I T E DH € I G H T E
STACXABL

TYPICAI- EX,AI/flPn-ES
OF' SITACKAtsNN-NTY
Figure 2-9

2-23
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2-25
5.3,1 S e l e c ti v e R a c k

The conventional bearn lype psllet isck consiste of structural uprights joined
by the pa1lec bearos \ t h i c h actually s u p p o r t t h e p a l l e t a n d 1 o s d . B e c a u se the
standard Navy pallet rack is t h e s a m e d e p E h s s t h e p a 1 1 e t ( 4 0 " ) , l o a d s night
have a tendency to fall t h r o u g h t h e b e a l ! o p e n i n g . T h e r e f o r e , Pallet s u pport
nembers ( load bars ) i r h i c h s p a n b e t w e e n t h e b e a n s a r e r e q u i r e d t o p r o vide
support for rhe 1oad, See CSA/FSS S p e c i f i c a t i o n M - R - 0 0 4 5 "Racks, S t o r age,
Loaded Pal let ".

6.3.2 Drive-ifl/Drive-through Rack

The drive-in rack structure cons ts of vertical posts with cantilever suP-
ported pa1let rails, This type of srtucture can be Mde eilher one p a l l e t or
several pallets deep. The single palLet arrangenent can b e u s e d i n Place o f
th€ conventional bean rack and is widely used in high r i s e S / R s y s t e n s , l , h e r e
the sdditional supporl of lhe one load per slot design is i n p o r t a n t ' t r t h e n d e _
signed several pallets deep, the syslem becones a high d e n s i t y s c o r a g e s y s t e n ,
similar to the autonated deep bulk system described in Seccion 3, but uaing
conventional fork lift trucks instead of automated equipment. T h i s arranae-
dent is shoqn in Fisure 6 25.

The fork lift truck operatioa in a drive-in rack must be confined carefully so
that ic does not bdnp tbe racks and danage nerchandisc or equipment. In soDe
cases, guide rails are used to prevent this problen. In addition, because of
the rigidity of the layout pattern generated by drive-in racks, tbey have a
tendency to develop excessive honeycombing and encoureae locked stock. They
also reduce the fte{ibility of the sarehousc storaSe operation. In general, a
drive in rack performs the san-. function as floor storage for itens lthich can-
not be self-supportins in stacks. The alternstive to these racks is the use
of self-supporcing pa1let fixtdres as discussed earrier, The use of drive-in
racks should be minimized, atrd che problem of non-stackable loads should be
dealt with using speciar pal1et support devices.

6.3. J StoraSF Equipn"nt ConsideraLions

If a shuttle cable systeo is used, crearance is required betueen lhe botton of

the paIIet and the top of the bean. To provide this space, entry bars or Pal-
l e t r i s e r s a l e a v a i l a b l e t o r a i s e t h e p a L L e t a b o v e E h e b e a n s . c o m p a r e dt o t h e
drive-in rack structure, the pallet riser nethod requires more vertical space,
r i t h t h e p o 6 s i b i L i t y o f a r e d u c t i o n i n t h e m a x i m L rn u E b e r o f v e r t i c a l loads,
When straddle or double reach equipment is used, a lower beamis used to rarse
che first load off the floor. This also reduces the totaL available €toraqe
he rght .

6.3.4 S a f e t y c o n si d e r a t i o n s

the design and 6eleccioo of a particular pa11et rack req,:ires a great deal of
engineering analysis and judgnent. A psllet rack is a structure and nust con-
form to structural engineering design praccices and principles, It is essen-
tial that pallet racks conforrn to the structural design procedures of the A.der-
ican Iron and Steel Instilute and the Anericen Institute of Steel Construc-
( Lwnl to page 6 - 3A)

6-28
]LI\T]E SIIOR.AGE PNCKNNG SYS1IEM
( T O C O N V E Y O RA N O / O R P A C K I N GO P E R A T I O N )
Figure 8-I0

I , 17
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Itrrarrrtt rLua iaca||rt ( u r r i L o A o S0 i s H a L f lt0 cttrt x€tG|ll
rN uxtT Lo 0l 0a tT€l aor€! '

iiAr5lcTrori/ rxvlI roiY

5t!tcr sYslars TxrTratt

ifourirrarls r!txlll rnf
L r r r T l T r o N !r r r o t f D t Y

PRrL!rDrliY 5Y9ttr

^9?LY r/r *^rro ro

3{L€C-tTXf !n3T[t rrTN

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o€ltiul|at co!l! ]r! rt

tfr aurlorra aldDuif

SYST'EM SEN-ECT'IONPR.OCEDURE
. EXXSTNNGts{JIN-DING.

figure l5-2

15 - 6
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Table 18-II

L8 - 2I
 cALUul,ArroA OF
sA-li.eLll CAI-CULATION
SA}PLE u! A COSTuuSr EQUATION
lquArru
Counterba lance Truck
2 high pP aa ll ll ee ll s t o r a 8 e

lnventorY Rela ted Costs

Building CoBl

l. Buildiog conEtruction Cost $ 35.45lsq.ft.

2. Annualized Buildin8 Construction co6t S I.418/sq.ft.
3. Annual Buildins op€ration cost S 0.50/sq'ft.
4. Building Area per Pallet Position 30.11 3q.ft.

Annual Building co6t per PalL€t Pogition S J7.75

Annuslized Storage Equipoent co6t per-?a]let Position $ 2.97

Transactiod Related Costs

l. Hourly l€bor Rate $ 1f.50/hr.

2- Standard Trsnsactioo TiDe per Issue 5-568 oin-
3. Activity Rate r i66ue/day
4. working Days per Year 250 days
5. Annual Lsbor Hours per Daily Transsctioo 23-20 nan-hours

Annual Lsbor co6t per Daily Transaction $ 266.80

l. Hourly vchicle operation co6t $ t.90/hr.

2. Annual Labor llours per Daily Transsction 23.20 Dan-hour8

Aonusl vehicle operation cost per Daily Tra.saction I44.08

Co6t Equationc

w i t h B u i l d i n g C o st

(Bulrdin8 Cost + StoraSe EquipDent CoEc) x tnv€ntory +

(Labor Co6t + Vehicle Co6t) x Transactions = Annual SyBten CoEt

($57.75 + $ 2.97)rnventory + (S266.80 + 944.08)rrangactione =

Annual systeD Cost - S60.72 I + S310.88 T

l.lithout Build iog co6t

(Buildiog operation Cost + storaSe EquipEent co6t) x Inveotory +

( I - a b o r C o G t+ V e h i c l e C o 6 t ) x T r a n s a c t i o o s= A n n u a l S y s t e o C o s t

( $ 1 5 . 0 6 + S2 . 9 7 ) I n v e n t o r y + ( 9 2 5 5 . 8 0 + $ 4 4 . 0 8 ) T r a n s s c t i o d=s
A n n u a l s y s t e o C o s t = $ 1 8 . 0 3 1 + 9 3 1 0 . 8 8T

Table 18-I2

18-22
 COST EQUATIONS

BINNABLESORDERPICKINC SYSTEMS

St o r a g e
Systeo Nee Constructlon Existiog BLrilding

r1anualPick Cart l I0.98r+S90.757 $ 0.61 I+S90.757

14 $ 0.80 1+590.757 S 0.62 I+$90.75r
2l s 0.77r+$90.757 s 0.62 r+s90.757

Orde! PickiDg t3 s 0.82 r + 5 7t.71 T $ 0.58 1+ S 7 1. 7 1 r

Truck 2A $ 0.71 I + $ 1 1 9 . 3 71 ' I 0.53 I + $1t9.37 T
2l $ 0.66 r + $12t.88 T $ 0.52 r + sr2l.88 r
3L I 0.64 1+ Sl24.5l T $ 0,51 I + $ 1 2 4 . 5 1T
Manned S/R 20 S 0.98 I + $152.19 T $ 0,81 I + Sl52-19T
2J S 0.85 I + Sl5l.8l T $ 0.73 I + 5l5l ,8r r
34 $ 0.77 I + 515I.62 T $ 0.68 I + $r51.62 r

1 S 2.44 1+ $ 85.42 r I 2.06 1+$85.427

S 2 . 7 8 1 + $ 1 0 0 . 2 7r S 2 . 5 t 1 + 5 1 0 0 . 2 7T
2l $ 1.00 I + Sll6.62 T $ 2 . 8 4 I + $ 1 1 6 . 6 2r

uini -S/R 2A S 1 . 3 0 I + $ 1 5 1 . 0 6T S 1.21 I + Sl5l.06 r

31 S 1 . 0 1 I + 5 1 5 4 - 8 7r $ 0 . 9 4 r + $ 1 5 4 . 8 7r
42 S 0 . 8 6 I + $ 1 4 1 . 0 5r S 0 . 8 0 I + $ 1 4 1 . 0 5r

I = Inveotory in 6helf boxes T - Transactions in 1348 I order6 per day

Cost base of I october 1983

Table I8- 20

18 - 37
t::

Li

Table L8-21

r8-38
 5 U : S T O R A GT
E J N I TL E V E L S

lsu

: 40

30

2 SU

I 5U

20 oo 4O,OOO 6O,OOO 8 0 ,o o o roo,ooo

r o , oo 30,000 5o,0oo 7o,ooo 90,ooo
] N V EN T OR Y _ 5 H € L F B O XE 5

ANNUAN- tsUNN,DNNG
COS1I
M A N U A LP I CK C A R T
E I N N A B L E SO R D E RP I C KI N G

22-t3
;

lrYPcAL 35 O sFv Its!ckl TRALtR

]-,

IIYPIC,{N- TRUCK APR.ON N-,{YOUII

Fi g u r ' l-l i

D-33
 HEIGHTS
A N DD O C K
A N DR A I L V E H I C L E
T Y PI C A LT R U C K

8ed Height o v e r a l I H e it h t llinimum

( i n c h e s) Ilock Leveler
Hinimum L e n g t h ( F t .)
Type of Truck Hinlmum

l2'-?" l3 ' -5r' 6 to lo

Container
..:,.',, l3' -6!' 5to8
50 6o
60 !8(;) 5 to l2
FI a t b e d 48
\6 4 8( b ) 5to8
0oubI e Axle Semi
q 8( b ) 8
5t rai ght Semi
C i t y D e li v e r Y \2 l{8 '
'1,_' t2'6" 4B 6to8

48 48 6to8
Stake Body \2
| 3'-0" r3 ' - 6 " \3 8 to 12
High cube Van 32 38
'Furni ture van 2\ l3'0" t3'6" 3 0( c ) 8

B '- 6 " t0'-0" l0 (c) 5 to l0

20 30
lo (c) B to l0

Low Boy
20
20 2\ l__'' 3 0( c ) 8 to l0
ll lr 5 (d)
Box Crr 4r
46 52 !B 5 to 5 (d)
Reefer Rail Cdr

Ranseof 48"-52".
(b) 50" if serving scmis onlY'
r'rmp to elcvate
N o n i n a t 4 8 ' , - 5 0 ' r d o c k r e c . , r n m e n d ewdi t h e x t e r i o r
truck to provide nominal 10" d o c k h e i q h t '
clearance belween
(d) Hinimumlenqth available determined bv required
rai I car .nd dock.

2l - l5
23.5.7

Typical overhead doors for truck docks are 8 to l0 feet high and 9 feet {ide'
An 8 foot high door sill typically provide a 12 foot high openins f r o n the
groond to top of door, Tlis leaves approximately 15 to i8 inches o f u n u s a ble
lrailer height due to door clearance when loading a standard l3'-6" t r a i l e r .
A 9 foot high doot allous sufficient space lo load highly conPacted loads w i t h -
out encouncering overhead restrictions due to door height' A l0 fool high
door will permit full access to the highest truck' Figures 23-11 ana 2l-18
show typical dinensions for a flush dock door.

23.5.8 Inter ior Layout

lnterior layout of docks includ.:s loading and unloadins areas as 'e1l as stas
ins and accumulation areas. Figure 23-19 shoss typical insirle dimcnsioos for
a dock. These dimensions allow for touline and load staginS a.eas.

Load acctrmulation space nust be estinat.:d dsinS typical shiPnent and t.uck
Ioadi g data. The anount of material to bc accumulated will rrcrPase as Lhe
order picking rate exceeds the loading rate. The space aill rea.h a P.ak ind
then decrease as order pickins ends and shipping renoves the backlos. SPice
estimates can be developed by maintaining a qork sheet sinilar to that rn Frg
ure 23-20. The rorkins day is divided into time blocks and the amount of rato
rial picked and shlpped is recorded. The dafa is convcrtPd lo area usins dP -
sity and area convr:rsion factors derived fron the charrcteristics of materiaL
processed by a part iculnr frcility.

2J.5.9 Do(k Levctcl c .rnd Ac. esr..r ie-

Dock design is conpleted by the addition of accessories which enh.rnce the per
formance, safety, and s e c u r i t y o f d o c k o p € r r a t i o n s . D o c k I e v e l e r s p e r m i t fork
trucks co rapidly load snd unload Lraiters by providing a perEanently mounted
bridge to the trailer ehich adjusrs to elevation diffete ccs betre€n the trail

Tr,o factors are crirical in dock leveler seloccion. The first factor is
lensth, rhich d e t e r n i n e s t h e m a x i m u mg r a d e v h i c h n u s t b c n . s o t i a t e d b y a t o r k
cruck. A naxioum grade of l0Z should not be exceeded. Recomnrc'Dded ock lev-
eler 1€n8ths for various dock heights 'ere Iisted previously in Tabt-.23-9.

The second factor in dock leveler selection is capacity. Dock levelers rre
subjecled to substantial inpact loads causcd by the notion of the fork truck,
truck and load treighc, and approach g.ade. Table 23-10 provides a sumnary of
estinated life based on capacity, use, and gross load, The life of a siven ca-
pacity dock teveLer, as sholrn in the tab1e, can ranae froD less than 5 years
to oore than 20 years, d€pending on use, gross load, and rated capacity.

Dock \teather seals (Figure 23-21) are a useful energy saving accessory shich
seals the gap bet\reen the truck and door and reduces the infiltra!ion of out-
side air into the uarehouse. Weatherseals are available as eithe! foaE pad
door seals or flexible nenber dock shelters. Each type has parlicular advan-
tages and drsadvanEages.
('h]I+i rc plge 23 - 11)
 STANDARD
OPERATION
SEQLENCE

C o u n t e r b a l a n c e dF o r k T r u c k - P a l 1 e t S t o r a g e

n.aruri^n s..n"ri.

Unload loads fron pallet rack

Move to s tag ing area
Stack Ioads in staging area
Return to pallet rack

Operat ion Sequence

Activity
frequ-.ncy Tola1 Time
D e s cr r p c i o n P e . C y c1 e Pe. Cycle

L D o c u m e nI P r o c e s s i n g 0.1t0 t 0.t10
Count prtces/process docs 0.880 I 0.880
3 Uou t/Drsm.'unt 0.450 I 0.450
RlxT,l I Rr(Ll)
5 0.120 L 0.120
Lift Losd 0.050 t 0.050
7 0,082 t 0.082
8 0. 090 I 0 . 0 90
9 R2xLl I R 2 (r , l )
l0 0.030 0.030
i.l Travel t o s a a ai n g R 3 x DI t R 3 ( D r)
t2 Stop 0.028 I 0.028
l3 RlxL2 L Rt(L2)
0.120 I 0.120
t5 0.050 t 0.050
t6 0.082 I 0.082
tl R2xL2 I R2(L2)
l8 0.030 I 0.010
l9 Travel to scoraSe R3xD2 t R3(D2)
20 0.090 1 0.090
2l I n t e r m e di a t e starts/stops 0.055 0.055(n)

Suminary Equation

rime = 2.212 + n(0.055) + R 1 ( L l + L 2 ) + R 2 ( L l + L 2 ) + R 3 ( D l + D 2 )m i , r .

P,llara h,n.lla.l nar.v.lr = I n

F-1