RightChain Pallets
RightChain™ Pallets: Pallet Storage, Picking and Slotting Optimization A logical, practical, and illustrative guidebook to optimizing pallet storage, picking and slotting
Edward H. Frazelle, Ph.D.
RightChain™ Pallets | Pallet Storage, Picking and Slotting Optimization
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1. 2. 3. 4. 5. 6. 7.
Introduction
Pallet Storage Optimization Pallet Picking Optimization Pallet Storage and Picking Optimization Designs Pallet Slotting Optimization
Best Practices Appendices
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Acknowledgements Co po ke rea, tHi oonnsd…a ., …J i .mARnoda mc ha, nRya foat ehle Rr sa mw oh so, hS ac ov tet t(rHu sPt eHdo ou ds )w, Ai t lhe xt haen dd eEs di g n( Cs aot fe rt ph iel il ra rwJaorhenh oDuesei rneg, …Bu..ffDaalove Hopkins, Steve Westphal, …. Tom Nabbe….. Jim Barber (UPS). Taylor Logistics, Blue
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Tab 1 le . of Contents Introduction
2. Pallet Storage Optimization a. Taxonomy
b. Floor Based Stacking Systems
i. Floor Storage Block Stacking ii. Pallet Stacking Frames 3. Pallet Picking Optimization 4. Pallet Storage and Picking Solution Design 5. Pallet Slotting Optimization 6. Appendices a. Best Practices b. Pallet Dimensions c. Pallet Types 7. Abouts a. About the Author b. About RightChain™ c. About RightChain.ai d. About RightChain™ Pallets 8. 9. Table of Figures 10.
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Chapter 1 Introduction
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RightChain™ Pallets | Pallet Storage, Picking and Slotting Optimization Os l voet tri nt hg e f oc or umr soer eo f t mh aonr e5 t0h0a nwtahrierht yo uyseeasr sa wn de dh ai svter i bo up tt ii omni z ceedn tt he res p, aolcl ec tu ps tyoi nr ag g em, opri ec k ti nh ga n, a 5n 0d mWiel l hi oanv es qbue ae rne f of eret ut , niant et etno pc or ou vnitdr iee tsh, iosnR ti gh hr et Ce hcaoi nn t™i nPeanl tl es ,t sa no pd t ii nm inzeaat irol yn es ve revr yi c emtaoj os ro mi ned ou fs tt rhye. wDeoerrl de ,’sMl ei tasduibnigs hoir, gTaanrigzeatt,i oa nnds iUnPclSuadminognBgPm, Caantyeropt hilelarrs,. C l or ox, C oca -C ol a , H on da , H P H ood , J ohn In hopes of helping many other organizations optimize their pallet storage and picking, wb ees tr epcreanctt li yc ecsoimn tpoi l et hdi sa ng du i dc oe bd oi foi ekd aonudr i no pt ot i mt hiez aRt ii og nh t Ca lhgaoi rni™t h mP asl,l emt se tohpotdi mo liozgayt i, olne aarsn ian gs se,r vaincde subscription AI offering hosted on the RightChain.ai platform. Following the RightChain™ Pallets methodology, this guidebook covers pallet storage ss yt os rt ae gmes a no pd t pi mi cikz iant gi o sny s(tCehmasp tseorl u2t i)o, npda lelseitg np i(cCkhi na pg t esry s4t)e, mp sa l loept tsi lmo ti zt iantgi oonp t(iCmhiazpa tt ei or n 3()C, hpa apltleert 5p )a,l lpeat lsl et ot roapgtei,mpiizcaktiinogn asnodl ustliootnt indges(iCghna(pCthear p8t)e. r 6) , use ca ses (Cha pt er 7) , an d best p ra ct ices in Einxdaumstprlye,saufrtoommoEtivviea,n…, .Coca-Cola, Honda, Caterpillar, …. Beverage, food, dairy, CPG, heavy Appendices include supplier listings, pallet types, template drawings, ….. Figure/map illustrating the implementations of RightChain™ Pallets RightChain.ai/pallets p i R n i i c c g l k h u i t n d C g i h n , a g a i n n o ™ d c c s u P lo p a t a l t l n i e n c t g s y . , i T s la h b e R o i o r g p h a t t i n C m d h i a z i e a n q t ’ i s u o i n p A m m I e b in n a t i s m e b d iz y e s s a u s b t s h s i e c g r n t i i p o n t t g i a o l n e c a o c o s h p t t o S im f K p i U z a / a l p t le i r o t o n d s t u o o c r f t a g p t e o a l a l i e n t t s d s o p t p o ic t r i k a m i cpoaml l ebti nhaa tni do nl i nogf pv ea hl l iectl es ,t oa rnadg es l mo toldoec ,apt iaol nl e. tPsat lol er at gset ocroangfei gaunrda t pi oi cnk(i en.gg . csot sotrsa ag reedteypptihc aalnl yd rheedi ug hc et )d, bfoyllo1w8%ingtoop3ti7m%iz.aTtihoen aanpdplaicnaatliyotnicsis. hosted on the RightChain.ai platform and provides the 6
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pT rhiomuagrhi l yt hbey tthwe oc osnucbe-rsny sf ot er mi ms pwr oovrekd hs taonrda-gi ne -dheannsdi t, yt ah ne d sitsodr ai cgtea t es dy sbt ey mt h es eolne-cht iaonnd ii ns v de nr itvoer ny apnr idm taur ri lnyo vbeyr tohfe t hc oen icteermn s f oi nr ph ai gl lhe t hsatnodrlai gneg. p Tr ohdeu cc thi ov ii ct ye aonf dt hter ahdaenodf flsi n ign sryesqt eumi r eids cdarpi vi teanl i(nSveectsitomne3n)t.. We conclude with a description of how the combined decision is optimized
Figure.1 RightChain™ Taxonomy of Pallet Storage and Handling Systems
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Chapter 2 Pallet Storage Systems 2.1 Floor Based Pallet Stacking Systems 2.1.1 Floor Storage Block Stacking 2.1.1.1 Stack Height Constraints 2.1.1.2 Honeycombing 2.1.1.3 Lane Depth Optimization 2.1.2 Pallet Stacking Frames 2.2 Static Rack Systems 2.3 Dynamic Rack Systems 2.4 Mobile Rack Systems 2.5 Pallet Storage Systems Solution Design
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RightChain™ Pallets | Pallet Storage, Picking and Slotting Optimization Ti nht eo Rf oi guhr t sCuhba-i cna™t eTg aoxr oi enso bmays eodf Po na l ltehteS pt or reasgeen cSey sotfe ma nsd cnl aastsui rf iee so fp at hl lee tr satcokri angget ys ypset:e(m1 s) F( 4l o) o Mr Bo ba si leed RSat ac ckk iSnygs tSeyms tse. mFsl o, (o2r ) bSat as et idc Rr aa cc kk i nS yg s tseyms tse, m( 3s ) iDn yc lnuadme i cf l oRoa rc ks St oyrsat eg me sb, laonc dk sptaal cl ekti nrga, c akn, dd opuabl lleet- ds et aecpk ipnagl l ferta mr aecsk. , Sat na dt i c drrai vc ke - isny/s dt er mi v se - itnhcrlouudgeh s ri na gc lke. - dDeyenpa ms ei lce crtai vc ke sr ay cs kt e ms yss tienmc lsu da er ep du es fhi -nbeadc kb yr amc ko, bpi lael l pe ta lfl leot wr arcakc. kE, aacnhd apl tael rl enta tsihv ue t t- l ei t ss yf sutnecmt iso. nM, po rboi lse, cons, and related costs - is described and illustrated below. 9
Figure 2.1. RightChain™ Taxonomy of Pallet Storage Systems The RightChain™ Taxonomy of Pallet Storage Systems classifies pallet storage systems into four sub-categories based on the presence of and nature of the racking type: (1) Floor Based Stacking Systems, (2) Static Rack Systems, (3) Dynamic Rack Systems, and (4) Mobile Rack Systems.
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2.1 Floor Based Pallet Stacking Systems Up anllliekte sftiaxcekdi npga lsl eyts treamc ksi, npgasl lyestt el omasd si ns uwphpi cohr t poanl lee tasnaorteh es ur ,papnodr t ae rde bsyt arcakcekdb de ai rme cst, l wy iot hn st ot apc koinn gosnyes, t he me nsc–e ftlho eo rnsatmo rea g“ep abllloect ksst taacckki ni ngg ,sayns dt epmasl ”l e. tTsht ae cr ke i na rgef rtawmoe st y. p e s o f p a l l e t 2.1.1 Floor Storage Block Stacking Ionn f tl oh oe rf lsotoorr ai ng es tbol or ac gk es tl aa nc ke isn, gt y, pp iacl al el ltyl o3atdos 1a0r el os at adcskde edeopn. tFol po oorf setaocrha goet hbel or cakn ds t as tcokri ne dg ihsapnadr, twi chu el anr liyn veef fnetcot irvyei swthuernn et hdeirne laarreg emiunlctri pe ml e epnatlsl e(tis. ep. es re vSeKrUa l (lsot aodc ks ok fe et hp ei nsgaumnei tS) KoUn ai trsee lrf e, caeni vde dw ha ne nd /colre awr i thhedi rgahwt sn aant do/noer tiinmvee)s, t wmhe ennt pb ruoddgue ct st ids oe ansoi lty ps et ar cmkiet d aonny tootph eorf astltaecrkninatgivsey.st(eBmeciasumseinnimo arla.)cking is required, the investment in a floor storage block Block stacking is easy to implement, and it allows near-infinite flexibility for fsltoaocrksipngacaerceoilnlufisgturraatteidona.nEdxdaemspcrleibceodnbfiegluorwat. ions and applications of floor storage block
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Figure 2.2 Block stacking in a CPG client’s raw material warehouse. (Lima, PERU) Notice the opportunity to increase building clear height and building cube utilization. RightChain™ Pallets identifies and quantifies that opportunity, and determines the optimal mix of pallet storage modes and pallet handling vehicles that minimizes pallet storage and picking costs.
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Figure 2.3 Block stacking in a Coca-Cola Plant Warehouse. (Charlotte, USA) Note that loads are stacked one high, two high, two and half high (by straddling adjacent stacks), and three high. Since the clear height is relatively low and the pallet loads stack efficiently on top of one another, floor storage block stacking is a very effective and efficient solution in this case.
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Figure 2.4 Block stacking with case picking front in a client-customer’s beverage distribution center (Greenville, USA). Lane-front case picking is a common case picking design in distribution centers in the consumer products and food/beverage industries; and where investment budgets do not afford racking for storage and/or conveyors for picking. RightChain™ Pallets was employed in this operation to optimize lane depths and slot locations to minimize pallet storage and case picking costs.
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Figure 2.5 An example floor storage layout optimized with RightChain™ Pallets for a large beverage company. The deepest lanes are devoted to reserve pallets. A pick pallet for each SKU is located at the front of each lane. As mentioned previously, some operations cannot afford or choose not to afford racking for pallet storage and/or conveyors for case picking. RightChain™ Pallets was employed in this operation to determine the optimal mix of pick vs. reserve pallets, the optimal lane depths for reserve storage, and the optimal slot locations for pick and reserve pallets.
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Figure 2.x Light weight pallet loads with uniform and stable surfaces are prime candidates for floor storage block stacking.
2.1.1.1 Stack Height Constraints Tp ahlel est t looraadg es tda ec nk isni tgy hi eni gbhl ot cokf es at acchk Si nKgU s(yi s. et .e tmh se igsr edaetteerr mt hi en es dt a ct ok i an gl ahr egieg hdte, gt rheee gbr ye atthe er wt heei gsht ot sr,algoea dd esnt as bi tiyl i)t. yA, f lmo oyrr i laoda do fc af apcatcoi rt sy , mp aa lyl ect ol no satdr aci anp satcai tcyk, lhoeai dg hst tsa bi ni lci ltuy d, ibnugi l dl oi an dg clear heights, and vehicle lift height capacities. Load Weights Tl ohaed sh ewaivl li ebre tchreu sl oh aedd, at nh de md aomr ea gl ei kde. l Sy oimt ies etxhaamt lpol ae ds so fa th et ha ve ybpo at tl loemt l oo af das sttha ac tk aor fe poaf tl leent satnadckfeerdtiolinzetro.p of one another include bags of cement, bulk raw materials, bulk liquids,
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Figure 6 The height of block stacking in one of our cement manufacturer client’s warehouses is constrained by product weight and the uneven surface formed by bags of bulk material. (Boston, USA)
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Figure 2.x Bags of bulk material and raw materials do no provide a stable surface for floor storage block stacking.
Floor Loading Limitations Lu inki ef o rhmi gi thyw, aaynsd, ddief fgerreeen t o ff l ol eo vr se l naerses . bAulill t mwu istth bdei f fceor ne ns itd elroeadd wwheei gnh td ect ae pr ma ciint ii ensg, appropriate and safe pallet load stack heights.
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Figure 2.x Pallet loads of bags of fertilizer and other dense raw bulk materials may be so heavy that a stack of more than one pallet may exceed the warehouse floor loading capacity.
Load Shape, Stability and Surface Uniformity Su onmi f oer ml o aadnsd hsat av be l ev et hr ye luonaidf osrumr f aa cned, tsht ea bglree as tt ea rc kt ihneg ms ua xr fi ma cue ms asnt adc ok ti nh ge rhse ni goht t. . T h e m o r e
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Figure 7 Block stacking in a client-customer’s aluminum can plant. Light weight and uniform pallet loads permit stacking four high.
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Figure x. Some pallet loads are so uneven and instable that they are essentially un-stackable.
Product Support Ts thaec kl oi nagd hb ee iagrhi nt .g Fcoarp aecxiat ymopfl ea, pi nr otdhuec tbaenv de riat gs ep ai nc kdaugsitnr yg , ptlhaey saammo uanj ot r orfo cl ea ri nb omnaaxt iiomnu mi n pt hr roedeu chtisg hi mbpe ac ac tuss el otahde bc eaar rbionnga. tSi oonm ien sciadreb ot hn ea t pe dl a sbt ei cv ebroatgt el e sp rcor de autcet ss ac asnt r bo en gsetra cl ko ea dd than those with less carbonation.
Building Clear Height
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RightChain™ Pallets | Pallet Storage, Picking and Slotting Optimization Lb ou ai lddsi n mg calye aor bhvei oi guhstlsy a nr eo tl obwe, fsl ot aocrk setdo rha iggeh be rl o ct hk asnt a ct hk ei n gb umi ladyi nbge ct hl eea ro nhl ye i rgehat s. oWn ahbelne storage alternative. Such is the case in the Evian warehouse in the figure below. 21
Figure 3 Block stacking in low-bay space in an Evian warehouse. (Tokyo, JAPAN) Floor storage may be the only reasonable pallet alternative with low clearings. Such was the case at the Japanese beverage wholesaler’s multi-story DC in the figure below.
Vehicle Lift Height Capacity Jliufst thleikigehwt citahpabcuiitlydionfgthceleparalhleetighhatnsd, olibnvgivoeuhsilcylelo. ads may not be stacked higher than the
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Figure x. Vehicle lift height capacity constrains maximum stacking heights.
Weather Wh eei gaht ht se;r ipsaor ftti ceunl aorvl eyr l ohoukmeidd iat ys . a Cf aocrtrourg ai nt edde tpe ramc kiangi ni nggmtaexni md su mt op aslol ef tt elno a di ns t ahcukmi ni dg cs ot ancdki thi oe ni gsh. t Hs eanr ec el,o ww ehre ni n sht ua cmkiidn gc opnadl li et itosn so.f Ocnoer roufgoaut erdc l ci eonnttsa irneecresn/tcl ya sleosc, a tme da xai mnue mw winacroerhpoourastee tinheShiingghahpuomreidaintyd. had to completely modify their storage schemes to
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Figure 2.x Humid and rainy weather impacts ……
Pallet Load Capacity Pt hael l el ot swleora dt hcea pl oaacdi t iwe se ivgahrty caasp aa cfiut yn, ctthi oens ohfo trht eer ptahlel e mt ’ sa xmi ma tue rmi a lp aa lnl edt csotna cs kt r uhcetiigohnt;. aFnodr egxreaamteprlel,omadectaalpapcailtlyettshahnavweoaodgrpeaaltleetrs.load capacity than plastic pallets which have a
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Figure 2.x Pallets may be made of wood, particle board, plastic, or metal. Each has a different pallet load capacity.
Honeycombing “dHu oe nt eo ytchoemnbeiendg ”t oi ss tao rree fae rs ei nngclee tSoK tUh ei n l oa shso or ifz sotnotraal gl ea ndee anns idt yv earntdi c anlect osl tuomr angoe f csat po raac gi tey. (eSxttoe rnisni gv em“ suhl tui pf fllei n gS ”KoUfsmi na t ear ihaol rt oi z oa cnct easl sl at hnee doers ivr ee rdt iScKa Ul sc.o) lTu hmenw/ sotradc k“ hwo noeuyl dc orme qb ui ni rge” wp haesn oc hmoesneonn t oo n dae sl carrigbee s twh aet hp hoef nf ol omo er nsot onr abgeec abul soec ki fs tyaoc uk i nl og o, kt h ea ts wt haet he fl foeockt s olfi kteh ea Th oh ne ehy oc onme ybc oa ms ab irnegs upl th oe nf tohme epnaot nt e ri sn oa lfseomi pl l tuys tsrpaat ce eds ai nn da sdwe sact rhi boef ds t oi nr aFgieg u( Fr ei g ux r ea n2d. x )x. below.
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RightChain™ Pallets | Pallet Storage, Picking and Slotting Optimization Honeycombing is the loss of storage capacity due to the floor storage block bstlaocckkiinngg apcrcoetsoscotol SreKqUusirwinitghionpaerlaantoer.s to refrain from not mixing SKUs in a lane and 25
Figure 2.x A view from above a large swath of floor storage block stacking in a bakery warehouse illustrating the “honeycombing” effect and look.
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Figure 2.x Floor storage honeycombing effect in a client’s beverage distribution center (Charlotte, USA). The combined effects of horizontal honeycombing (a) – the loss of storage capacity in front of the most rearward stacks – and vertical honeycombing (b) – the loss of storage capacity on top of existing stacks – yields very low effective net storage density if lane depths are not optimized. RightChain™ Pallets was employed to optimize the client’s lane depths in more than 200 warehouses and distribution centers; more than doubling warehouse storage density and yielding CAPEX avoidance well into in the $tens of millions.
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Figure 2.x Vertical honeycombing losses in one of our client’s warehouses prior to RightChain™ Pallets.
Honeycombing Simulation Ba rerl aonwg ei sd ai nh ot hnreeyec,o smi xb-idnege ps i ml aunleast .i oInn. tBhoet hb lbolcokcsk so nh atvhee eliegfht t e( Le any bo luotc kA )s, t aLcakn ep o1s iitsi osni xs op tohsei tri osni ds ed; eaenpd. LL aa nn ee 32 iiss tthwroe ep po os istiitoi on ns sdde ee pe poonnobnoet hs i ds ied, easn. dI n4t hpeo sbi tl oi ocnkss do enetph eo nr i gt hhet (dLifafyeoreunttBl)a,neeadchepltahnse. is six positions deep and has no flexibility to be reconfigured into The simulation runs for six days, and assumes that each SKU has a daily rweipt hr edsreanwt ianl gr aatne oS Kf oUn. eT shtea cski mpue lra dt i aoyn. Tmhoen ci tool rosr etdh eb lnouc mk sbaerre oof c oc uc cpui epdi e, dw ipt oh s ei tai oc hn sc, otlho er
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RightChain™ Pallets | Pallet Storage, Picking and Slotting Optimization oi ncccruepaasne cs y2, 2a%n d, atnr advterlarveeql uwi ri tehdi nwliatnhei ns ad el ac rneea. sBeys obpyt4i m1 %i zi. n g t h e l a n e d e p t hs , o c c u p a n c y 28
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Figure 2.x RightChain™ Pallets honeycombing simulation. Layout A is on the left and Layout B is on the right.
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Figure 2.x Example floor storage block stacking operating rules. Block (a) represents the honeycombing losses in front of SKUs N, O, and P. Block (b) is the space in front of SKUs N, O, and P released for use by other products by withdrawing from the “short stacks” first and/or from re-warehousing the short stacks. Block (c) represents the space released for storage by re-warehousing all the “short stacks” into single-deep pallet racking.
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Figure x. Operating efficiencies for floor storage block stacking. (a) Non-wall located blocks should be accessible from both ends and should be operated with flexible lane depths. In the example, a seven deep block could be utilized as four-deep on one side and three-deep on the other; or five deep on one side and two-deep on the other; or even seven deep. (b) Aisles should be designed and designated as either “main aisles” or “cross aisles”. Main aisles have heavier, multi-purpose traffic and should be wider accordingly. (c) Cross aisles should be designed and designated exclusively for floor storage block stacking pallet handling. (d) It is sometimes efficient and effective to locate blocks along main aisles to increase the number of fronts and value-added transactions along a main aisle. (f) Walls should almost always be utilized for storage to make best use of floorspace devoted to aisles.
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Lane Depth Optimization Hf uonncet iyocno mo fbl iannge dl oespstehss .vLaerty’ s gl or eoakt layt, annoenx-al imn epal er l (yF, iagnudr e sb oxrtdoeyr )l i. n e n o n - i n t u i t i v e l y a s a In the example, a lot of twenty-four pallets of the same SKU have arrived to the wb ea rset ho roeuds ea. sT ehieg hpta l“lsettascakrse” sotfa ct hkreede t ph ar el lee ths i geha .c Ah .s Tahree seui gl th, tt hs et atcwk se nmt ya-yf obuer sptaol rl eetds iwn i lal variety of configurations. One storage configuration would be to house all eight stacks in a single (deep) lsat no er a(gFei gaui srlee .2H. xo, wa )e. vI enr ,s ot hda ot isnagm, tehfer ol ontt , wa os uwl de lol na lsy t oh ceceunptyi roe nl ea npea, l wl e ot ’ us l wd ibdet h“ oacl oc unpg i et hde” w s u e n o v t u e il l n d t t h h b e , e a t n w “ d o e c n tw c t u y o p f i o t e h u d i r r ” t d h f s o p o r a f l t t l h h e e e t i e e n i n g t h t h i t r e h e e s t i t g i a m h ck t e s a t t r h a e c e k b s f e i i r w n s g t a , s w s r i e t e c h m o d n o r d a v , w e d t n h f i f r r r o d o m , m f o t t h h u e e r t l l h a a , n n e e fi . . f tThh, es il xa tnhe, At the other extreme, all eight stacks could be placed along the main storage ami si nl ei m( Fi zi eg utrhee 2h. xo, nde y) ;c oe mi g bh itn (gs heaf fl el ocwt )a nodn em- daexei mp ilzaen el isf.t Tt rhui sc k“ f lt ar at ”v eclo ns pf iegeudr sa t iaonnd wp oa lul el dt apcocretsiosn; hoof wtheevfelro,oornspe-adceeeips dlaenveosteydietlodaaisvleesr.y low storage density, because such a high There are at least two other possible configurations between those two e( Fx itgr ue mr ee2s ;. x ,t wc )o. El aacnhe sc, o fnofui gru- dr aetei po neha ca hs i (t sF iogwu rne u2n.ixq, ube) d aeng dr e ef ooufrh loanneeysc, otmwboi-ndge, espt oer aa cghe density, and occupancy costs.
Figure x. 24 pallets of the same product arriving into a warehouse
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Figure x. Stacked 3 high, 24 pallets become 8 stacks.
Figure x. Alternative lane depths for eight stacks of three pallets each of a single product; one lane, eight deep; two lanes, four deep; four lanes, two deep; and eight lanes, one deep. The storage density and resulting occupancy cost are a non-linear function of lane da ve eprt ahg. eF fi lgouorres pxa ci se oa c cl aunpei e dd ebpyt ht hoe pl toi tm) iazna dt i oonc c suipmaunlcayt i coons. t Satroer ac go em pd ue nt esdi t ya s ( amfeuanscutri oe dn oafs l at hn ee o t d h c e i c p s u t p p h a , a r l n o t c i t c y s u i c l z a o e r s , t c m s a . a s ( e x N , i m a o t u l e a m n t e h s a t d a t e c t p k h t i e h n g o s h f h a n e p i i n g e h e o t y , f i l e o th l a d e d s o d th b im e je e m c n ti a s v x i e o i m n f s u u , n m a c n t s i d o t o n a r i s a c l g u e e r d v d i e m e n i e s s n i n t s y o io n a n n - a l d i l n p t e h r a e o r p m a e n i r n d ti i e m n s o u . n I m n - cmoanyt i nn outo ub se , tmh ea koivnegr ai tl lc oo pmt pi mu taal tbi oenc aa lul syedtihf fei clui fl tt ttroudc ke rtirvaev tehl es poepet di maanl dl avneeh idcel ep tphr os od luuctti iovni t. )y Ta hs ias function of lane depth have not yet been incorporated into the optimization.
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Figure x. asdf;laksjdf;laskjdfasdf
Floor Storage Lane Depths and Lift Truck Travel Speeds Ot hnee iomf pt ha ec tf roefqluaennet ldyeopvt ehrsl ooonk el idf t pthr eu nc ko mo ep ne ar ai tni nf lgo os pr es et odrsa ga ne dl a np er oddeupctthi voi tpyt.i mL iifzt a tt ri ounc ki ss sHheonucled, ds leoewp edr o lwa nn e isn rde es eupl te ri nl asnl oews , etrr al vi fet l itnr ug cskl otwr aevre la ss pt he ee dy st, r laovwe le rd eperpoedru icnt itvoi tay , l aanned. it nr ac vr ee al ssepde epdr oadnudc tv de ha mi c laeg/eo. pTehr ao tuogrh pirt ordaur ec tl yi v ii tsy, tmh eu si tmbpea ci tn coof rlpa onrea dt eedp tihnst oo nl a nl ief t dt er up ct hk optimization. Figure 2.x below illustrates the lane “narrowing” effect and the need for lift truck or epceernattloyr sc otmo ps ll eotwe ddaonwa nl y saiss tohf etyh ed ri mi v pe adc et eopf el ra ni ne tdoe fpl tohosr osnt oirnatgr ea - ll aa nn ee st. r Fa vi geul rdei s2t a. xn ci se sa, intra-lane travel speeds, and intra-lane travel times.
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Figure x. Floor storage block stacking in a large beverage warehouse. (Sao Paulo, BRAZIL). Lift trucks must drive slower in deeper lanes, and lift truck speed and productivity must be taken into account in lane depth and storage mode optimization.
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Figure x. Impact of travel speed on ……
RightChain™ Lanes | Floor Storage Lane Depth Optimization Ti mh pe aRc ti g ohft Cl ahna ei n ™d e Lp at hnse so nA I hmo noedyucloe mwbiitnhgi n, sRt oi grha tgCehda ienn™s i tPya, l li enttsr at-al ak ne se itnr taov eal c dc oi sut na nt ct ehse, idnettrear-ml ainnei n gt r af ovre le ascphe eS dKsU, ’ sa int d’ s ot hp et i moavl elraanl le dper po dt hu; ctthi vei tlya noe f d el ipf tt h t rt hu ac kt moipnei mr aitzoerss t hi ne ss ui mmu l oa tf e os cac nu dp aenvcayl ,u al at be so re, vaenr yd pvoe shsi icbl el e csot so trsa. g Re i cg oh nt Cf ihg auirna’ st i oLna nf oe r De ev pe tr hy SOKpUt i/mp irzoadt iuocnt ac on nd sdi deet er irnmg i no cecsutphaenlcayn ec odset patshat hf uant cmt i ionni mo fi zset so rtahgeet do et anlspi tayl laent ds tloarbaogre/ vaenhdi cpl ei c ckoi ns gt s caoss ta, function of lift truck travel speeds and productivity. An example lane depth optimization for a large consumer products company aS pKpUesa rasn idn lFaingeusr et hxa. tb eslhoowu. l dT hbee f isgtuorree di l l ua sc tcroartdeisn fgol yr . eFa icghu rl aen ex dbeepl ot hw t hi se an ul ma nbee rd oe pf tohf od pe pt itmh si ztahtai ot nmfionri ma ilzaer gt he ebteovtearl apgael lceot ms tpo ar angye. Ta hn ed oppi ctki mi nigz actoi sotns .c o m p u t e s t h e m i x o f l a n e
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Figure x. RightChain™ Pallets floor storage lane depth optimization.
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Figure 11 Example RightChain™ Pallets floor storage lane depth optimization. Asdf;lkjsdf;lkjLane Depth Optimization
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Loads in a block are retrieved last-in-first-out (LIFO). Hence, if highly restrictive (amfeoarseibslteriscttotrhaagne lmotetohrocdo.de date) FIFO requirements are in place, block stacking is not Since only one SKU can be effectively stored in a lane or stack, empty pallet sTphaecreesf oarree, icnr eoart de de r wt oh i mc ha icnatnani no thbi gehuut itl ii lzi ez da t ieof nf e cotfi vt ehley auvnatiilla abnl e esnt toi rr ae glea npeo si si t ei omn ps ,t itehde. ll aa nn ee dd eepp tt hh o( np ut i mm bi zeart i oo fn l oa na da lsy ss itso rdeedv ef lroopme dt hf oe r aai srl ee )c emn tu cs lt i ebnet ci sa rperf eusl leyn tdeedt ei rnmFiingeudr .e 3A. Trehceomlamneenddeedptthhroyuigehldtihneganthaleysilso.west floorspace requirement for each item is Ii sf luannde edr eupt itlhi zseadr. eI ft ot hoedl ea enpe , da es pi ts htsh ae rcea tsoe oi ns ht ho re t p, thooot ol a, rt hg ee af l opoorrst pi oanc eo fi nt hf reofnl ot oorfs tphaec eb ai sc kd epvaol lteetds to aisles. If the pallets are not easily stackable, too much of the available clear height is lost.
Increase in storage density examples from Coke Brazil
Total cost per pallet…. Storage capacity Storage density Number of fronts… How this delayed the capital investment of a major beverage company. Capex avoidance.
2.1.2 Pallet Stacking Frames Ps taelel el tusnt iatcskmi nagdfer aump eos f adr ee cekist haenr df rpa oms et ss. a St ttaacchkei nd gt of r satma ne ds aarrde wp oo or tdaebnl epaa nl l de t se noarbsl ee l ft-hceo nutsaei rn et do sintaackmminaimteurimalasmevoeurnatl olofasdpsacheig. h. When not in use, the frames can be disassembled and stored Stacking frames are commonly used when loads are not stackable and when other racking alternatives are not justifiable. Also, since stacking frames can be leased, they are
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RightChain™ Pallets | Pallet Storage, Picking and Slotting Optimization pstooprualgaerdwenhseintythinerwehiastaissnhoorrmt-taellrymopspenikfeloionrisnpvaecnet. ory and the frames are needed to increase All of the storage density losses due to honeycombing described earlier for block stacking also apply to stacking frames. 40
Figure 12 Pallet stacking frames. (NTT Logistics, Tokyo, JAPAN)
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Figure 13 Inbound pallet stacking frames. (Ford, Atlanta, USA)
2.2 Static Racking Systems r S a ta c t k i . c racking systems include single deep pallet rack, double deep pallet rack, and drive-in 2.2.1 Single-Deep Pallet Rack pS irnogvlied- idnege pi mpma el lde ita trea c(kpi incgk - fi as c ea ) sai cmc pe sl es tcoo nesat cr hu c ltoi oand sotf o rme de t a( li . eu. pnroi g hh tosn eayncdo mc rboi ns sg-)m. eUmnbl ei kr es bi ml omc ke dsitaatcekl yi nagv, awi l ha be nl e ai n psai nl l ge lte s- dpeaecpe ri sa cckrienagt. e dA l bs oy, tshi nec er erma cokvianlg osfu ap pl oo ratds, eav eprayl lleota od p, setnaicnkgi ni gs hb eei“gshtta ci sk endo”t ilni mt hi teedsabmyet vheerstti caaclkcaobliulimt yna(nbda/yo)rocf rsutsohr aagbei l istpyaocfe.t he l oa ds , a nd m ul ti pl e S K U s c an
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Figure 14 Single deep pallet rack (American Cancer Society’s National Logistics Center, Atlanta, USA) Loads do not need to be stackable and may be of varying heights and widths. In isnusptpanorctessowrhdeercekitnhge. load depth is highly variable, it may be necessary to provide load A typical single-deep rack position costs between $40 and $50. The major as pd av caen tdaegveoitse fdu tl lo aacicsel es ss i -b itlyi tpyi ctaol layl l5u0n%i t tl oo a6d0s%. Tohfet hmea aj ovra idl ai sbalde vfal onot ar gsep iasc et h. eAasmaoruens tu ol tf, ihno cuasseess awt h leeraes tt h tewr eo a rpea ltlhe rt se e i on r am of arcei npga l lpeet sr poenn- dh iacnudl aor f at on St hK eU , sat os tr oa rgaeg ea ims l ee t hmo adyt hbaet preferable. Selective pallet rack might be considered as the "benchmark" storage mode, as tgoari na gs et ws yhsi ct ehmo st hbeer nseyfsi tt efmr os mm at hy eb eu sceo mo fp aart elde af os tr as do mv aen tsaegl ee sc tai vned pd ai sl al edtv raanctka gfeosr. SMKoUsst whose storage requirement is less than three to five pallet loads.
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Figure 15 Single deep pallet rack with pallet staging bays. (London, ENGLAND)
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Figure 16 Single deep pallet rack with all-clear aisle lights. (Otto, Munich, GERMANY)
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Figure 17 Single deep selective rack. (Caterpillar, Atlanta, USA) Double-Deep Pallet Rack Da dovuabnl et a- dg ee eopf tpwa lol -edt ereapc kr sa cakr fea cmi negr se l (yp se er pl eecnt idvi ec url aa cr ktso tt hhae t aai sr lee )t wi s ot hpaatl lfeetwpeor sai ti si ol enss adr ee enpe. e dTehde. w 7 In 0 e m % c o a n s to t n c o 7 a t 5 s a e % s s s a u u m 5 ti 0 e li % z th a a t a i i t o s a l n e 5 s o 0 p f % a t c h t e r e s u a e a v v s i a n p i g a la s c b e i l s s e a a v c o h i p n i e e g n v s i e n w d g i s v ll e b ( r d e s u u a s e c h s t i i o n e v g h e le o d - n d s e e in y e c c p o e s m w e b l e e i c n c t a g i n v ). e o r n ( a l 8 y c 0 k a . % n H t i o t c o w ip e a 8 v t 5 e e % r a , utilization is common for single deep racking.)
Figure 18 Double deep pallet rack. (Storemax, London, ENGLAND)
Double deep racks are typically used when the storage requirement for an SKU is five pp aa ll ll ee tt ss . o( rA sgsriegantienrg aSnKdU swwhiet nh opnrloydau sc itn igsl er pe cael lievte odn a- hnadn dp itcok eddo ufbr leeq-udeene pt l yr aicnk imn gu li tsi pn loenss eonf stiwc aol
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RightChain™ Pallets | Pallet Storage, Picking and Slotting Optimization sdienecpe, oandeooufbtl eher etawcoh pf oorskitliiof tniss irneaq ufai rcei ndgf oisr satuotroamg ea/tirceatlrl yi ewv aal s. t ed .) S i n c e p al l ets a r e s t or ed t w o 46
Figure 19 Double deep pallet rack accessed via double deep reach truck.
Drive-In/Thru Rack Dp rroi vvei d- iinn gr as tcokrsa geex tl ea nn de s tf hr oe mr e5dtuoc 1t i 0o nl o aodf sadi sel eep sapnadc e3 tboe g5ul no a wd si thhi gdho. uDbrl iev-ed-ei enpr apcaklsl eatl l or awc ka lbi fyt tprouscski btl oe bd er icvaeu si en tt ho e t hr ae c rka cc ko nssei svtesr aol f puapl lrei tg hpt o cs oi tliuomn sn sa nt dh a st t ohraev eo rh or reitzroi envt ea l ar api al sl l et ot . s uT ph pi so ri st
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RightChain™ Pallets | Pallet Storage, Picking and Slotting Optimization ps taol rl eatgsea, te aachheliegvhetl abbeoi nv eg tshuaptpoofrtthede liinf dt et rpuecnkd. eTnht liys ocof nt hs et routcht ei orns . p e r m i t s m u l t i p l e l e v e l s o f p a l l e t 47
Figure 20 Drive-In Rack in a Honda Parts DC One drawback of drive-in rack is the reduction of lift truck travel speed needed for safe navigation within the confines of the rack construction. Another drawback is the t i h n h o e n r a e c c y a k c s o e is m w b b e i i s t n h t g u b l s o l e s o d s c e k f s o r s s t i s a n l c o c k e w i n n t g o o , m m lo o e a r d d e i s u t h m s a h n v o e u o l l o n d c e i t b S y K e S U r K e s U t h r s o i e u w v l i d e t d h b e t w e h n i o t h o u r s a e m d L o i I r n F e O a p l a d a l n l i e s e c t . s i p A o li n s n - a e h r a a e n n s d u d . l t A w d s i r t w i h v a e a s - retrieval discipline to free up each lane as quickly as possible.
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RightChain™ Pallets | Pallet Storage, Picking and Slotting Optimization Drive-thru rack is merely drive-in rack that is accessible from both sides of the rack. It ri se tor fi teevne du as et dt h feo or t shtearg ei nngd . l oTahdes sianmae fcl oo nws-itdherrua tf iaosnhsi of on r wd reirvee -ai npraal lcekt ai ps pl loya tdoe dd r ai vt eo- tnher ue nr ad c ka n. d 1.3 Dynamic Racking Systems D(PyBnRa)m, aicnrdamckoinbgilesypsatlelemtsrafocrkp(aMllPeRt )s.torage include pallet flow rack (PFR), push back rack Pallet Flow Rack If rnopma lol entef leonwd roafc ka lsot aodr as gaer el acnoen tvoe yt ehde (oFt hI FeOr .) oAns sak laot ae dwihs ereel mc oonv ve de yforro, mr otl hl eer fcroonnvt eoyfo ar , sotro rr aa gi l es lhainghe tthheronuegxhtplouatdpaadllveat nsctoesratgoethaendpircektrfaiecvea. l The main purpose of pallet flow rack is to provide and good space utilization. Hence, it is used for dt hi soasde viat enmt asg ewoi tf hp ahlilgeht fpl oawl l erta icnkviesntthoer ye xtpuernnsoev;e$r2a0n0dt ow$i t5h0 0s epveerr apla pl l ae lt l es tt os roang -ehpa onsdi .t i oTnh. e m a j o r 48
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Figure 23 Pallet flow rack (Rear View)
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Figure 24 Pallet flow rack. (New Installation)
Figure 25 Pallet flow rack replenishment.
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Push-Back Rack s s P t t u o o s r r h a a - g g b e e a , c e i k t m s r p w a l c o e
k y
p n h
r g t o a
v a n
i d r
e i t s l h - l g e
a u s
f i t
o d - r i e n c d e
- f i c o
r a f s r t
t r - h
o ie e
u r t p f u
d o t
e r a e
w e p a a
l c y
a h n v
e p e a h ( l t i l c
y e l
p t e
i c l
p o a
u a ll
s d y h . e t A w
s s o
t h a t e
o l o o
f a t
iv d h e
e i r s p l
a p o ll
e a d
t c s
s e d i d n
e i e n th
p to e )
i g i
d a
a l
ltahneef br oa nc kt ionft oa tshteo rl aang ee tloa ncer e, at ht ee rwo oemi g hf ot rotfhtehaedrdei tmi oani nail nl og aldo.a dA saau tl oo amdaitsi craelml y oavdevdafnr coems ra ec mc eas isni bi nl eg al ol oandgs tt ho et ha ei s rl ea. c kI nf aacded. i tHi oenn ,c sei, necveear lyl So Kf tUh/el apnuet ahwa sa ya al on addr et ht raite vi sa il mt amk ee sd ipaltaecl ey ad to tuhbel er-adceke pf a rc ae c, kt h. eArne ai sd nv aonnt ae ge ed of ov re rs pd er ci vi ae l- ilni f tr at rc uk ciks at ht taat cthhme reen it ss na os wn eaesdt ht oe dc ra isvee wi ni tt ho mt h ee d ri ua cmk taon df a st ht -emr eo viisn gn oS KvUe rs t iwc ai tl hh ot hnreeyec ot om bt ei nn g p. a lPl eutssh -obna-chka nr da c. k Ti hs ea pc opsr to porf i at yt ep i fcoarl push-back rack is in the range of $150 per pallet position.
Figure 26 Push-Back Rack in a Honda Parts DC (Honda, Atlanta, USA)
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Figure 27 Two-Deep Push Back Rack, American Cancer Society, Up Against a Wall, No FIFO requirement (American Cancer Society, Atlanta, USA)
Pallet Shuttle Systems
Mobile Pallet Rack Me not bi riel e r po awl l eotf rraacckkss at roe me sosveen at iwa lal yy sf ri no gml e a- ddej aecpe np ta lrl ae tc kr arcokws so. n Twh eh euenl sd eorrl yt irna gc kpsr pi necrimp ai tl t ii sn gt haant av iasllueas b al er es poancl ey . j uAsct ci fei es ds two hae np at rhtei cyu al arre sbt eoirnagg eu sr eodw; ti sh ea crheisetv eo df tbhye mt i mo vei ntgh e(ym ae cr eh aonci cc ua pl l yy i nogr manually) the adjacent row and creating an aisle in front of the desired row. As a result, less
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RightChain™ Pallets | Pallet Storage, Picking and Slotting Optimization tphaal lne t1 s0t%o r aogf et hael t fel ronoar tsipvae cs e. iUs ndf eovr ot ut enda tteol ya, i tshl ees p, aa nl l de t srt eo trrai ge ev adl epnrsoi tdyu icst itvhi teyhiisg ht he es t l oo wf aens ty ooff at nh ey oa nf tdh ee xapl et enrsni va et i, vaensdwf oe rhsal voewc- omnos vi di ne gr eSdK. UHs ewn ci teh, mo noeb ti loe trharcekes paar lel ej ut ss toi nf i -ahbal ne dw. hTehnes cpoascte oi fs tsycpairccael mobile rack is in the range of $250 per pallet position. 53
Figure 28 Mobile pallet rack is most easily justified in situations where occupancy costs are extremely high and throughput requirements are fairly low, as is the case in KAO’s CPG slow mover’s warehouse near Tokyo. (KAO, Tokyo, JAPAN)
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Figure 29 Mobile Pallet Rack Installation
Pallet Storage Systems Selection The key to selecting the appropriate pallet storage system configuration is to assign each SKU to a pallet storage system whose storage and productivity characteristics match the activity and inventory profile of the SKU . The figures below assist this matching pi nrcol cuedsisn. g cFoisgtu, rset o5r .axg ei s dae ns us imt ym, laorayd oaf ctchees ski be iyl i tf ye ,a tt uh rr eosu gohf peuatc hc app aalcl ietty ,s ti no vr ae gnet osryys taenmd location control, FIFO maintenance, load size variability, and ease of installation.
Pallet Storage System
Percent Loads on Pick Aisle
Product Rotation
Product Protection from Damage
Ease of Install
Easy to Re-Configure
Same Face for Pick and Restock
Special Vehicle Required
Rack Cost per Pallet Position
Floor Storage Single
Few
LIFO
Iffy
Easiest
Easiest
Yes
No
$0
100%
Random
Excellent
Easy
Easy
Yes
No
$40
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Deep Pallet Rack Double Deep Pallet Rack
to $80 $40 to $80 $30 to $60
~50%
LIFO
Good
Easy
Moderate
Yes
YES to Reach Back Pallet
Drive in Rack Push Back Rack Pallet Flow Rack
Few
LIFO
Iffy
Moderate
Difficult
Yes
No
~10% to ~40%
LIFO
Iffy
Moderate
Difficult
Yes
No
$80 to $150 $200 to $300 $400 to $800
FIFO
Iffy
Difficult
Difficult
No
No
Pallet Shuttle System Mobile Pallet Rack
<40%
LIFO or FIFO
Iffy
Very Difficult Very Difficult
Very Difficult Very Difficult
Depends
No
<10%
Random Moderate
Yes
No
$500 to $1000
Figure 31 below illustrates an example pallet storage mode analysis. The example is taaskae nf uf rnocmt i oan poafr ttihceu l caor scta as en da nadv ac ai lna nb iol ti tby eogf elnaebroarl iaz ne dd ssipnacceet. h eTph ree af enraelnycs ei s r iengdi oi cnast evsa rtyh ew mi d oe sl yt economically appropriate assignment of popularity-inventory families to pallet storage modes.
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RightChain™ Pallets | Pallet Storage, Picking and Slotting Optimization
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Figure 31 Example pallet storage mode optimization for a large grocer.
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RightChain™ Pallets | Pallet Storage, Picking and Slotting Optimization
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1 Pallet Handling Systems In rank order from least expensive to most and simplest to most complex, the most popular pallet handling systems are: • Conventional Vehicles • walkie stackers (WS), • counterbalance lift trucks (CBLT), • sit-down counterbalance lift trucks (SDCBLT) • stand-up counterbalance lift trucks (SUCBLT) • driverless counterbalance lift trucks (DLCBLT)
• Narrow Aisle Vehicles • straddle trucks (ST), • Very Narrow Aisle Vehicles • turret trucks (TUT),
• straddle reach trucks (SRT), • sideloader trucks (SLT),
• swing fork turret truck (SFTUT), • swing mast turret truck (SMTUT), • hybrid trucks (HYT), • Automated Vehicles • automated storage and retrieval (ASR) machines, and • automated guided storage/retrieval vehicles (AGSRV).
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RightChain™ Pallets | Pallet Storage, Picking and Slotting Optimization
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Figure 32 Pallet handling vehicles. The applications, pros, cons, and related costs of each system are described below. 1.1 Conventional Vehicles Wsyastlkemiess.tackers and counterbalance lift trucks make up the class of conventional pallet handling Walkie Stacker Ao p we raaltkoi re sstteaecrkse rf r oa ml l o wa sw aa l kpianlgl e pt ot soi tbi oen l ibf teehdi n, ds t at hc ek evde, hai cnlde . t rI annas psoi trut ae tdi osnh owr ht edries ttahnecrees i. s Tl ohwe tdhersoi ruegdh, ptuhte, swh ao lrkt i et r as vt aecl kdeirs tma nacye sb, ea na dp pl roowp rvi ea rt et i. c aAl sttyopr ai cgael hweai gl khite, as nt adc kae lro wc a nc osstta sc ok l ul ot iaodns i as mh aanxdi mo fuf mr e qouf i rt he dr e) eo fl opaadl lse thri geht r, i ec ov satl /s pi un t at hwea ryaanngde tor uf c$k1 l0o, 0a d0 i0n, ga/nudn loofaf edri ns gt.h e d u a l p u r p o s e ( n o
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RightChain™ Pallets | Pallet Storage, Picking and Slotting Optimization
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Figure 33 Walkie stacker in receiving operations for a large biotech. (Carlsbad, USA)
Counterbalanced Lift Truck At os st ht aebni lai zme e l ioma dp sl i ecsa, rcroi eudn t ae nr bd a ll iafnt ecde loi fnt tar umc kass te mi np tl ohye af rcoonutn ot ef r tbhael a tnrcuec ki n. t hC eo ubna tcekr ob fa tl ahne cter ul ci fkt turnui cqkuse ml oaayd bc oe ngf ai gsu or ar t bi oant tseor ny ap ov we ret ri ceadl . mBaes st .i dTehs ef ohreki gs h, to tl ihme ri t aa tt itoanc hi smgeennt es r ma l layy abr eo uunsde d2 5t of elei ftt. Aa v ac oi l ua nb ltee rwb iatlha no cpeedr attri nu gc kc amp aa yc i tni eost ubpe t uo s1e0d0 t, 0o0s0t oproeu nddo su ba lned dc eoes pt .i n Ct hoeu nr at enrgbeaol af n$c3e0 ,t0r0u0c k. s a r e
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