FACILITIES PLANNING AND

DESIGN LAB
“FACILITIES DESIGN OF 1000 SQM
WAREHOUSE”

SUBMITTED BY:
Abegail D. Pagurayan
Corita Luzzini Doronila
 FACILITIES NEEDED FOR THE WAREHOUSE

Aisles
Aisle width depends on the type of lift trucks used. Aisles should be wide enough for
trucks to make a single turn into the row. Making them too narrow will save space but
slow down the store-and-retrieve operations and result in greater damage. Cross aisles
can reduce travel times but take up valuable space. Balance the two.
Rows
Design rows wide enough to allow drivers to carry loads in and out without causing
damage. Lift trucks fitted with side shifters allow drivers to move loads a few inches
from side to side so they can work in narrower rows.
Docks
The number of shipping doors needed depends on how long it takes to load and unload
trailers, the number of trailers handled, and how many shifts are worked. The dock is
the busiest and most dangerous part of the warehouse. Don’t squeeze down the space.
MATERIAL HANDLING NEEDED
1. Hand trucks
This is a simple, two-wheel hand-operated truck or trolley, usually with a metallic frame and a
toe-plate. Hand trucks are designed to ease the transportation of small items. Some come in a
folding variety that packs flat when not in use.
2. Pallet jacks
A pallet jack, truck or pump is used to transport materials that have been stacked on pallets.
These jacks have twin forks, which slide under the pallet. The handle is then used to raise the
forks with a pumping force, creating a hydraulic action that lifts the pallet, and enables
transportation.
3. Walkie stackers
A walkie stacker is the next stage up from a pallet jack or truck. The basic design is the same,
except that the stacker is motorized. The ‘truck’ aspect of the walkie stacker is similar to the fork
alignment and design of a forklift truck. The whole assembly can be moved around by hand, and
pallets can be lifted to the second shelf of a warehouse stacking system. They are ideal for
small capacity items, indoor use and on concrete floors. Walkie stackers are also less
expensive than forklift trucks.
4. Platform trucks
A platform truck is simply a frame and platform on wheels. The platform can be stacked by hand
when a large number of small items require transportation, or can be loaded using another item
of material handling equipment. This is ideal for small-to-medium size operations, or as a
speedy logistical solution for large organizations.
5. Order Picker
The order picker is a small-sized forklift truck that’s larger than a walkie stacker and is capable
of bearing more weight. Order pickers can typically retrieve and replace stacked items from
heights of between 10 – 30 feet.
6. Sideloader
Sideloaders are used to load and unload from the side of the machine, as opposed to the front-
positioned forks of a standard forklift. Sideloaders are best used in narrow aisles and doorways,
but they are not as maneuverable as forklifts.
7. AGV
The AGV is a mobile ‘robot’ that follows wires, markers or other indicators in the floor. AGVs can
also use lasers, magnets or cameras for guidance. They are often used in large-scale industrial
applications to move materials around a warehouse.
Bulk Material Handling Equipment
If your warehouse involves the movement of a large number of items, then the key to efficiency
is movement in bulk. The more items you can move at one time, the more efficiently your
warehouse will run. Here are some types of equipment that will enable you to do just that.
8. Conveyor belts
A conveyor belt is a motor-driven belt that forms part of a conveyor system. Items that require
transportation are simply placed on one end of the belt, and the motorized system moves them
to their destination.
9. Stackers
A small, hand-propelled or motorized truck that’s used to lift items off the ground and onto
shelving. This is deal if you are making the most of your warehouse space in having a stacking
system. They are cheaper to run than forklifts, and are ideal for small-to-medium applications.
10. Reclaimers
A machine that has a rotating scoop at one end of a conveyor system. The scoop gathers up
small, loose items and places them on the conveyor belt. The items are then transported along
the belt until they reach their destination.
11. Bucket elevators
Also called a grain leg, a bucket elevator is used to transport small, loose items vertically. It is
usually a motorized device, but can be hand-cranked as well. A series of small buckets are
attached to a belt. The buckets scoop up the materials when at the bottom of the belt, then lift
and disperse the materials at the top. Some bucket elevators may be inclined.
12. Grain elevators
Grain elevators are towers that contain a bucket elevator or a conveyor. The grain is scooped
up from a lower level and safely deposited in the required storage facility. This is ideal for large-
scale operations.
13. Hoppers
Another device for handling small, loose items, a hopper is basically a large funnel. The items
are placed in the top of the hopper, and gravity moves them down to the bottom, which features
a narrow aperture, which allows for flow control. The only disadvantage with hoppers is that they
can become blocked fairly easily.
14. Silos
Silos are typically used in agricultural applications. They are used to safely store grain, or silage
(fermented feed). They are also commonly used for the bulk storage of coal, cement, wood-
chips, sawdust and even food products.

Software
Over the last 10 years, there has been an explosion of software available for managing
warehouses. Designers promise it will reduce inventories and labor costs while
improving customer service, inventory accuracy and storage capacity. What they may
not say is that it can take over your operation, tying up a quarter of your workforce to
satisfy its demands for more and more information.
You do need a means of tracking your inventory and the software that fits your needs
can bring most of the promised savings but beware of bells and whistles that sound
good. They can become a cacophony when you try to implement them.
Picking
Order picking is the most labor-intensive operation in the warehouse. The objective is to
get the correct product to the customer in the shortest time while maintaining high
productivity.
Whether you are picking individual parts from cases, picking cases from a pallet or
picking full pallets, specialized equipment is available. Again, work with suppliers, study
the options and ask to see demonstrations.
Whatever the type of picking, making the most frequently picked SKUs the most
accessible will reduce picking times.
There are many more decisions that will confront you than we could cover in this article:
where is the best location; should you lease or buy; do you need a central distribution
center; etc. Do not become overwhelmed. Take them one at a time and they will fall into
place.
WAREHOUSE