chapter 1:-Introduction

What is warehouse??
[7]In its simplest form, warehousing is the storage of goods until they are needed. The goal of
warehouse operations is to satisfy customers needs and requirements while utilizing space, equipment,
and labor effectively. The goods must be accessible and protected. Meeting this goal requires constant
planning and ongoing change.
according to[1] frazelle the warehouses are classified into following:Raw Material Warehouse where raw materials are held at or near the point of induction into a
manufacturing facility.
work in progress warehouse where partially completed assemblies and products are held at various
points along an assembly or production line
finished goods warehouse where inventory is held to balance and buffer the variation between
production schedules and demand.
Distribution and warehouse distribution centre where accumulation or consolidation of products from
various points of manufacture within a single firm, for a combined shipment to common customers.
fulfillment warehouse for receiving , picking and shipping orders for individual customers.
[7] The Various operations carried out at warehouse:Dock Operations
The basic dock functions are unloading and loading carrier shipments, checking the shipments for damage, and
verifying the counts stated on the delivery receipt. The driver should note all damage and shortages on the delivery
receipt before the receipt is signed. All delivery and/or shipment paperwork should be routed to the proper
department within the organization.
Basic dock equipment usually includes a hand truck and a pallet jack. If there is a high volume of shipments, the
pallet jack may need to be electric or there may need to be a powered lift truck. In the end, the characteristics of the
shipments usually determine the equipment needed.
Space directly adjacent to the dock doors should be sufficient to accommodate the average daily volume of receipts
and outbound shipments. Just how much space depends on the time it takes receiving to check shipments and move
them into the storage systems, your ability to control when carriers deliver and/or pick up shipments, and how soon
outbound shipments start being staged each day. There should also be space for empty pallets, containers, carts,
and the like used to hold inbound goods. You might save floor space by storing these above and/or between the dock
doors.
Unless you expect to receive inbound shipments continuously throughout the day, it usually makes sense to handle
inbound and outbound shipments in the same area of the warehouse. Doing so usually requires less space, less
equipment, and fewer personnel.

Receiving Operations
Receiving duties often include the dock functions. The receiving function is the starting point for inventory control in
the warehouse. It is also the function best suited for gathering information needed for keeping product details
accurate and current. And if copies of the product are to be routed or stored, receiving should handle their delivery
and storage. Any and all essential data should be gathered at this stage, and it should be documented on the
receiving reports.
The basic functions of receiving include verifying product quantity, preparing receiving reports, and routing those
reports to designated departments. Receiving also should prepare received products for movement into the storage
and picking systems. Receiving also should pull the stock needed to process backorders.
Receiving usually needs a desk, a computer, a filing cabinet, and other furniture or equipment associated with the
duties to be handled. A small office or a designated space near or in the dock area is all the space normally required.

Storage Operations
Storage functions are usually an extension of receiving department duties. The basic functions of storage are the
movement of products from the dock area to a holding location, the recording of the location and quantity, and the
updating of storage records so that the product can be found easily when it is needed. Retrieval of products from
holding locations may also be assigned to storage operations and/or may be a function of picking operations.
There are two basic methodologies for setting up a storage system:

You can simply use the floor, lining pallets up in rows and stacking pallets of like product on top of each other.
This method is usually referred to as bulk storage. This can be a valid option for a warehouse with a very low
ceiling. It can also be a good option for storing many pallets of the same product.

You can install pallet rack and/or shelving in rows. This widely accepted method, usually referred to as rack
storage, usually makes good use of available space and is cost effective so long as the ceiling height allows at
least three levels of full pallet storage. The higher the ceiling, the more cost effective rack storage usually
becomes.

Storage normally occupies most available warehouse space. Before selecting storage equipment, we must know the
dimensions and weights of the unit loads to be handled. The unit loads will normally be cartons stacked on wood
pallets. The pallet used determines the width and depth of the unit load. The standard pallet is 40 inches wide and 48
inches deep. The height of the pallet plus the height of the cartons stacked on the pallet determine the height of the
unit load. Because the height of cartons usually varies, we will need to set the height at a level that best
accommodates the various carton heights. Once we know the unit load specs, we can work with equipment vendors
to determine which pallet racks and lift trucks best meet the needs. Generally it is best to select equipment that
somewhat exceeds the weight requirements. The added degree of safety is well worth the slightly higher cost.
The size of the product received usually varies from a few cartons to a few pallets. If this is the situation, we might
consider setting up the storage area to accommodate the various volumes because it will make better use of the
storage space.

Picking Operations
Picking operations is defined as the assembly of products ordered by customers. This is a simple function, yet it is
time consuming. As you evaluate and/or setup your picking operations, efficiency should be a major goal. After all,
customers expect their orders to be processed quickly, not just accurately.

Experts suggest that there are two basic ways to set up a picking system. At the same time, parts of both concepts
can be combined. Thus there are three ways:

in the first way picker will pull the products directly from the storage locations. This method works best when the
products are shipped in case quantities or when most orders include a lot of full cases. this is a storage picking
system.

in the second case stock is moved to picker. This usually means the picking system is a stand-alone system,
but it could be in a defined section of the storage area. this is called as stand-alone picking system.

the third is the combination of the above. This usually means that the picker pulls fast-moving products from
storage locations and slow-moving products from a separate picking system. This is called a hybrid picking
system.

The equipment needed to hold the products will vary according to the picking method you use. Pallet racks likely will
be used in a storage picking system. Static shelving, carton flow racks, and pallet racks might all be used in a standalone picking system. (The use of other equipment, such as a carousel, is also possible.) A hybrid picking system
might use all the equipment mentioned above.)
Before we decide how to set up your picking system, we must decide how we will assemble customer orders. There
are two ways to accomplish this:

we can batch pick, pulling multiple orders at one time. This method is common when pickers must travel long
distances to assemble orders.

we can pull one order at a time. This method is common when travel is not a major factor and when customer
orders average one to a few products.

evaluation of the following order characteristics offers the best solution for order picking operations
(1) Determine the percentage of orders that contain a number of full cases:

If the percentage exceeds 50, a storage picking system may be your best option.
If the percentage is 25 to 50, a hybrid picking system should be considered.
If the percentage is less than 25, a stand-alone picking system is likely the best choice.

(2) Evaluate the line-item characteristics of the orders:

Determine the percentage of orders with one line item. If we pick one order at a time, these orders can be sorted
by zone, regardless of the picking system used.

Determine the percentage of orders with two or three line items. If we single pick, most orders can be assembled
without having to travel through the entire picking system.

Determine the percentage of orders with four or five line items. If we single pick and use a stand-alone pick
system, approximately one-half of the orders can be assembled without having to travel through the entire
system.

If the sum of the above percentages is 60 or more, picking one order at a time makes good sense. If the sum is
less than 40%, batch picking should be considered. If the sum is 40%-60%, single or batch picking can be
equally effective.

Packing Operations
Packing is the process of packaging for shipment the products ordered by customers. If they are batch picked, orders
are separated and checked for accuracy during the packing phase. for single picking, orders are checked only if we

do not hold pickers accountable for accuracy of the orders. As a general rule, products are packed into shipping
cartons, the air space is filled with a packing media, and the cartons are sealed. If the shipment mode requires it,
cartons are stamped, labeled, and otherwise marked as needed.
If packages are poorly packed, the possibility of damage increases greatly. The shipping carton should be of such
strength that it cannot be bent or crushed easily, and it should be packed so that the products will not shift during
transit. The equipment needed in the packing area includes tape machines, box knives, and various stamps. If we do
not use a conveyor system, we will need a packing table. If we do use a conveyor, we will likely pack on the conveyor
itself. we might also need some equipment to apply or affix labels to the cartons.

Shipping Operations
Shipping operations is where the final steps are taken to prepare orders for shipment via the requested mode of
transit. The tasks performed usually include weighing each carton, recording shipment information in a manifest
system, and applying address labels generated by the manifest system. If the shipment is going by mail, correct
postage is applied. If the shipment is going by truck or air-freight carrier, a bill of loading is completed. After packages
are processed, they are sorted to pallets or tubs so they can be moved to the shipping dock for carrier pickup.
It is usually considered shippings responsibility to ensure that all shipments are picked up the day they are ready to
ship and that all shipping paperwork is routed to the correct departments at the end of each shipping day.
Material handling systems
In order to carry out these functions ,various material handling systems are used, according to Siddhanta [2]Ray
material handling is the art and science involving the moving, packaging and storing of substances in any form.
The term system has many meaning depending on the field where applied. A general definition of the term could
be: a complex unity formed of many often diverse parts subject to a common plan or serving a common purpose. The
important characteristics of a system is that the parts, called subsystems, are interrelated and guided by an objective
for which the system exists.
the following are the [2]10 principles which should be followed while designing a new material handling system at a
facility:

Planning Principles:- All material handling should be the result of a deliberate plan where the needs,

performance ,objectives and functional specification of the proposed methods are completely defined at the
outset.
Standardization Principle:-Material handling methods, equipment, controls and software should be

standardized within the limits of achieving overall performance objectives and with sacrificing needed
flexibility , modularity and throughput. anticipation of changing future requirement.
Work Principle:- Material handling work should be minimized without sacrificing productivity or the level of

service required of the operation.

Ergonomic Principle :-Human capabilities and limitations must be recognized and respected in the design

of material handling tasks and equipments to ensure safe and effective operations.
Unit Load:- Principle Unit loads shall be appropriately sized and configured in a way which achieves the

material flow and inventory objectives at each stage in the supply chain.
Space Utilization Principle:- Effective and efficient use must be made of all available space. System

Principle:- Material movement and storage activities should be fully integrated to form a coordinated,
operational system which spans receiving, inspection, storage, production, assembly, packaging, unitizing,
order selection, shipping, transportation and the handling of returns.
Environmental Principle:-Environmental impact and energy consumption should be considered as criteria
when designing or selecting alternative equipment and material handling systems

Automation Principle:- Material handling operations should be mechanized and/or automated where

feasible to improve operational efficiency, increase responsiveness, improve consistency and predictability,
Life Cycle Principle:- A thorough economic analysis should account for the entire life cycle of all material

handling equipment and resulting systems

System Principle:- Material movement and storage activities should be fully integrated to form a
coordinated, operational system which spans receiving, inspection, storage, production, assembly,
packaging, unitizing, order selection, shipping, transportation and the handling of returns.

Unitization
[2]Unitization of load is an important concept in Materials Handling. The basic concept is to move maximum load at a
time so that the number of moves for a definite quantity of load to be moved is minimum and so is the cost of
handling. The concept is practiced, wherever, possible, almost universally.
[2]unitized load may be defined as: A number of items, or bulk material, so arranged or restrained that the mass
can be picked up and moved as a single object, too large for manual handling, and which upon being
released will retain its initial arrangement for subsequent movement.

The major advantages are:(i) It permits handling of larger loads at a time and thereby reduces handling and transportation
costs.
(ii) Loading and unloading time of unit load is substantially less than when handled as loose/
individual material.
(iii) Unitized loads are less susceptible to damage and loss during movement from one place to
another.
(iv) It offers safer handling and transportation compared to those of loose materials.
(v) Unitized load, even made of irregular shaped items, generally become stable and well
shaped. This offers a number of advantages like stable storage, uniform stacking to greater
heights and increased storage space utilization.
(vi) For unitized load, individual item labeling may be avoided.
(vii) The process of unitization often protects loads from foreign elements.
(viii) Unitization generally provides a basis for standardization of handling system and equipment
within the plant as well as at the receiving and shipping points for transportation.

There are also disadvantages associated with unitization of loads These are:
(i) There is a cost of unitization and de-unitization.
(ii) Unitization generally involves additional support and material for restraining the loose
articles. These unitization medium increase the weight of the final load to be handled.
(iii) Unitization essentially means deployment of equipment, which necessitates capital investment.
(iv) Containers are often used for unitization. Movement of the empty containers results in
additional handling cost and problem.
(v) There is possibility of damage due to mishandling of large amount of load.
(vi) Movement of unitized materials may get hampered due to absence of transfer equipment.
Material Handling Equipments Are Classified Into:
Transport Equipment

Positioning Equipment

Unit Load Formation Equipment

Storage Equipment

Identification and Control Equipment

the each of these in detail are
Transport Equipments:- These equipment are used to move materials from one location to other(e.g., between
workplaces, between a loading dock and a storage area, etc.). Material also can be transported manually using
no equipments. Transport type of equipments include various types of conveyors , cranes, and industrial trucks.
[4]A conveyor system is a common piece of mechanical handling equipment that moves materials from one
location to another. Conveyors are especially useful in applications involving the transportation of heavy or bulky
materials. Conveyor systems allow quick and efficient transportation for a wide variety of materials, which make
them very popular in the material handling and packaging industries.
The conveyors offer the following advantages

Conveyors are able to safely transport materials from one level to another, which when done by human
labor would be strenuous and expensive.

They can be installed almost anywhere, and are much safer than using a forklift or other machine to
move materials.

They can move loads of all shapes, sizes and weights. Also, many have advanced safety features that
help prevent accidents.

There are a variety of options available for running conveying systems, including the hydraulic,
mechanical and fully automated systems, which are equipped to fit individual needs.
there are many varieties of conveyors in the market specific to particular purpose for which they are used.
Belt conveyer, Wheel conveyers, Roller conveyers ,Chain conveyers Slat conveyers among the few.
[5]Crane is a type of machine, generally equipped with a hoist, wire ropes or chains, and sheaves, that can be
used both to lift and lower materials and to move them horizontally. It is mainly used for lifting heavy things and
transporting them to other places. It uses one or more simple machines to create mechanical advantage and
thus move loads beyond the normal capability of a human. Cranes are commonly employed in the transport
industry for the loading and unloading of freight, in the construction industry for the movement of materials and in
the manufacturing industry for the assembling of heavy equipment.
the cranes are classified into jib crane, bridge crane, gantry cranes and stacker cranes depending on its use.
[2]Industrial Trucks:-These are manual or power driven vehicles suitable for movement of mixed or unitized load,
intermittently, where primary function is maneuvering or transporting. The vehicle/truck is physically
moved along with the load from one point to another via a flat or slightly inclined route. these can be furthur
classified into hand truck, powered truck or forklift truck.
[2] unit Load Formation equipments:- Unit load formation equipment is used to restrict materials so that they
maintain their integrity when handled as single load during transport and for storage.
The major types of unit load formation equipment are pallets, skids, sleep sheets, tote pans, cartons, bags, bulk
load containers, intermodal containers, shrink wrap, palletizer's and conventional stripper plate palletizers.
[2] Storage Equipments:- The equipment that falls under this description is usually non-automated storage
equipment. Products such as pallet racking, shelving, casters and carts, among others, belong to storage and
handling. Many of these products are often referred to as "catalog" items because they generally have globally
accepted standards and are often sold as stock materials out of Material handling catalogs. various types of
racking systems fall under this category i.e. single deep rack, double deep rack, gravity flow , cantilever type etc.
[1] Identification and Control Equipment:- Identification and control equipment is used to collect and
communicate the information that is used to coordinate the flow of materials within a facility and between a
facility and its suppliers and customers, bar codes, RF tags , magnetic stripes , machine vision system falls
under this category.
The scope of the project is to study and design a new material handling system which will improve the
productivity at the warehouse , the above information should be considered while designing and implementing .

Bibliography
1. Edward Frazelle (2004) world-class Warehousing And Material Handling, Tata McGraw hill edition
2.siddharta Ray(2008) Introduction To Material Handling New Age international Publisher
3. Keshava Chanda Arora, Vikas V. Shinde Aspects of Materials Handling Laxmi Publications ltd.
4. http://en.wikipedia.org/wiki/Conveyor_system
5. http://en.wikipedia.org/wiki/Crane_(machine)
6. http://en.wikipedia.org/wiki/Material-handling_equipment
7. http://aaupwiki.princeton.edu/index.php/Warehouse_Operations