Warehouse Design & Layout

Transkripsi

1 Warehouse Design & Layout - Perancangan Fasilitas pada Warehouse- 10 Oleh : Debrina Puspita Andriani, ST., M.Eng Teknik Industri, Universitas Brawijaya [email protected]

2 Mission of A Warehouse 2

3 PERSEDIAAN! penyeimbang dan penyangga akibat adanya perbedaan antara perencanaan produksi dengan permintaan aktual KONSOLIDASI BARANG! penggabungan barangbarang dari beberapa pabrik atau gudang kecil sebelum dikirimkan DEPO!Gudang penyangga yang mendekati pasar, untuk mempercepat respon supply Jaringan Distribusi dan Warehouse 3

4 Receiving and shipping (penerimaan dan pengiriman) Identifying and sorting (pengidentifikasian dan penyaringan) Dispatching ke penyimpanan Picking the order (pemilihan pesanan) Storing (penyimpanan) Assembling the order ( perakitan pesanan) Packaging (pengemasan) Dispatching the shipment Maintaining record (perawatan produk) Main Functions in the Warehouse 4

5 RECEIVING & SHIPPING OPERATIONS 5

6 Reserve storage and pallet picking Replenishment Case Picking Replenishment Broken Case Picking Direct put away to reserve Accumulation sortation packing and utilization Receiving Cross-docking Shipping Typical warehouse functions and flows 6

7 The Flow of Material 1. Transportation facilities on one side of building Highway or Railroad R S R S R S Receiving & Shipping Operations (1) 7

8 The Flow of Material 2. Transportation facilities on two adjacent sides of building R S R S R Receiving & Shipping Operations (2) S 8

9 The Flow of Material 3. Transportation facilities on two opposite sides of building Highway or Railroad R R R S S S Receiving & Shipping Operations (3) 9

10 1 Determine what is to be received and shipped 2 Determine the number and type of docks 3 Determine the space requirements for the receiving and shipping area within the facility Receiving & Shipping Space Planning 10

11 1. Determine what is to be received and shipped Receiving & Shipping Analysis Chart Company( Date( Raw(Materials( Finished(Goods( Prepared(by( Sheet( of( Plant(Supplies( 1( 2( 3( 4( 5( 6( 7( 8( 9( 10( 11( Unit(Loads( Size(of( TransportaGon( Material(Handling( Frequency( DescripGon( Shipment( Type( Capacity( Size( Weight( of(shipment( (unit(loads)( Mode( SpecificaGons( Method( Time( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( (( Receiving & Shipping Space Planning 11

12 2. Determine the number and type of docks Waiting line analysis The number of docks Determine the time required to load or unload a carrier Type of Docks Rail docks Truck docks Drive in docks Poisson distribution or Simulation Time study : work sampling, PMTS, etc. Receiving & Shipping Space Planning 90 0 docks Finger docks 12

13 for R/S Area Minimum Maneuver Jenis Alat Material Handling Minimum Maneuvering Allowances (ft) Tractor 14 Platform truck 12 Forklift 12 Narrow aisle truck 10 Hand-lift (jack) 8 Four-wheel hand truck 8 Two-wheel hand truck 6 Manual 5 13

14 3. Determine internal receiving and shipping area requirements Personnel convenience/offices A receiving hold area Trash disposal & recycling bins Pallet and packaging material storage/palletizing equipment The truckers lounge Buffer or staging area Material handling equipment maneuvering Receiving & Shipping Space Planning 14

15 DOCK LOCATIONS 15

16 Lokasi dan Layout Dock 16

17 Dock Levelers Bumper Pads Dock Shelters As the interface between a dock at a given height and variable-height carriers As the interface between a fixed dock and a moveable carrier As the interface between a heated/ air conditioner dock and an unheated/non-airconditioned carrier Dock operations planning 17

18 1 2 3 Material flows Expansion directions (Receiving and shipping activities) Modular design of storage/warehouse facilities with expansion alternatives 18

19 STORAGE OPERATIONS 19

20 Stacking Frames Cantilever Racks Selective Rack Flow Rack Racks for Automated Storage and Retrieval System (AS/ RS) Storage Medium 20

21 Stacking Frames 21

22 Cantilever Racks 22

23 Selective Rack 23

24 Flow rack 24

25 AS/RS (Automated Storage / Retrieval Systems) 25

26 Person-to-item (fixed) Rak penyimpanan statis (diam) dan orang/mesin yang mendatangi lokasi barang dan mengambilnya. Item-to-person (random) Barang yang berjalan dengan menggunakan material handling device (seperti conveyor) menuju lokasi penerimaan yang telah ditentukan. Flow rack merupakan salah satu media yang dirancang menggunakan sistem ini. Storage and Retrieval Systems 26

27 Penentuan lokasi gudang yang didirikan merupakan permasalahan awal dan kritis dalam perancangan gudang. Permasalahan berikutnya adalah berapa unit gudang yang harus dibangun serta luas dari tiap unit gudang tersebut. Faktor yang harus dipertimbangkan dalam pembangunan gudang antara lain: Lokasi Pelanggan/Pengguna, Tingkat layanan yang diharapkan kepada pelanggan, Harga tanah, biaya sewa, pajak, biaya konstruksi, dan asuransi. Lokasi Gudang 27

28 Tinggi bangunan Storage media yang digunakan Luas lahan yang tersedia S/R methods Barang yang disimpan Layout gudang tergantung beberapa hal, yaitu: Jalan/lintasan pada rak penyimpanan Layout Gudang Secara Umum 28

29 Layout Of Warehouse Store 29

30 Prinsip yang diperhitungkan dalam perencanaan gudang: Popularity Frekuensi perpindahan barang, masuk (receiving) dan keluar (shipping) Similarity Item yang diterima dan dikirim bersamaan, seharusnya disimpan bersama Size pengelompo kan berdasakan ukuran fisik barang Characteristics Jenis dan sifat barang yang disimpan Utilisasi ruang termasuk luas lantai storage kemudahan akses Storage Layout Planning 30

31 Randomized storage policy Dedicated storage policy Cube-per-order index (COI) policy Class-based storage policy Shared storage policy Storage Policies 31

32 Dirancangan berdasarkan hukum Pareto: 80% the turnover will be as the result of 20% of material stored. SLOW MOVING ITEMS MEDIUM MOVING ITEMS FAST MOVING ITEMS Entrance/Exit Sehingga 20% material yang menentukan tersebut dipertimbangkan untuk disimpan dan diambil dalam jarak yang paling pendek. Barang yang masuk dalam kategori fast moving diletakkan mendekati pintu masuk atau/dan keluar. Penyimpanan barang berdasarkan Popularitas barang yang disimpan 32

33 190$180$170$160$150$140$130$120$110$100$100$110$120$130$140$150$160$170$180$190$ 180$170$160$150$140$130$120$110$100$ 90$ 90$ 100$110$120$130$140$150$160$170$180$ 5% 170$160$150$140$130$120$110$100$ 90$ 80$ 80$ 90$ 100$110$120$130$140$150$160$170$ 160$150$140$130$120$110$100$ 90$ 80$ 70$ 70$ 80$ 90$ 100$110$120$130$140$150$160$ 150$140$130$120$110$100$ 90$ 80$ 70$ 60$ 60$ 70$ 80$ 90$ 100$110$120$130$140$150$ 15% 140$130$120$110$100$ 90$ 80$ 70$ 60$ 50$ 50$ 60$ 70$ 80$ 90$ 100$110$120$130$140$ 130$120$110$100$ 90$ 80$ 70$ 60$ 50$ 40$ 40$ 50$ 60$ 70$ 80$ 90$ 100$110$120$130$ 120$110$100$ 90$ 80$ 70$ 60$ 50$ 40$ 30$ 30$ 40$ 50$ 60$ 70$ 80$ 90$ 100$110$120$ 110$100$ 90$ 80$ 70$ 60$ 50$ 40$ 30$ 20$ 20$ 30$ 40$ 50$ 60$ 70$ 80$ 90$ 100$110$ 80% 100$ 90$ 80$ 70$ 60$ 50$ 40$ 30$ 20$ 10$ 10$ 20$ 30$ 40$ 50$ 60$ 70$ 80$ 90$ 100$ Dock Optimum Dedicated Storage Layout 33

34 Barang mudah busuk/tidak tahan lama, seperti ikan, sayur, buah, dll. Media penyimpanan dirancang dengan temperatur yang khusus. Barang yang berdimensi khusus/ tidak standar. Barang yang dimensinya tidak umum baik panjang ataupun luasannya. Sehingga memerlukan rak/ media simpan yang fleksible dari dimensi dan ketinggiannya. Barang berbahaya/beracun, seperti cat, pernis, bahan kimia yang mudah meledak, dll. Penanganan khusus terhadap barang ini diatur dalam regulasi safety dan harus menempati lokasi yang aman dan terisolir. Barang berharga/kecil. Penanganan barang yang mudah dicuri dan bernilai tinggi harus mempertimbangkan penjagaan dan lokasi penempatan yang aman. Rencana Penyimpanan Berdasarkan Karekteristik Barang Barang yang bersesuaian. Barang yang akan rusak jika ditempatkan berdekatan dengan barang yang mempengaruhinya secara kimia /fisik. Seperti margarin, jika disimpan diruang pendingin bersamaan dengan ikan, maka bau ikan akan mempengaruhi/merusak aroma margarin. 34

35 ORDER PICKING OPERATIONS 35

36 Work$Element$ Method$of$Elimina<on$ Equipment$Required$ StockUtoUpicker(System( Traveling$ U(Miniload(AS/RS( Bring(pick(locaGons(to(picker( U(Horizontal(Carousel( (( U(VerGcal(Carousel( Documen<ng$ Automate(informaGon(flow( (( Computer(Aided(Order(Picking( AutomaGc(IdenGficaGon(System( LightUAided(Order(Picking( Reaching$ Present(items(at(waist(level( (( VerGcal(Carousel( PersonUaboard(ASRS( Miniload(ASRS( Sor<ng$ Assign(one(picker(per(order( and(one(order(per(tour( (( Bring(pick(locaGon(to(picker( StockUtoUpicker(System( Searching$ Take(picker(to(pick(locaGon( PersonUaboard(ASRS( Illuminate(pick(locaGon( PickUtoULight(System( Extrac<ng$ AutomaGc(Item(Pickers( Automated(dispensing( RoboGc(Order(Pickers( Weigh(count( Scales(on(Picking(Vehicles( Coun<ng$ Prepackage(in(issue( increments( Order Picking Work Elements & Means for Elimination 36

37 Procedure( Pickers(Per( Line(Items(Per( Period(Per( Orders( Pick( Shi]( Discrete( Single( Single( Single( Zone( MulGple( Single( Single( Batch( Single( MulGple( Single( Wave( Single( Single( MulGple( ZoneUBatch( MulGple( MulGple( Single( ZoneUWave( MulGple( Single( MulGple( ZoneUBatchUWave( MulGple( MulGple( MulGple( Methods of Order Picking 37

38 Tompkins, White, Bozer and Tanchoco. (2010). Facilities Planning (4th Ed.). New York: Wiley. REFERENCES 38

39 Satu kelompok = 7 orang Urut Presensi Dikumpulkan dalam softcopy pada minggu depan Referensi : Tompkins, White, Bozer and Tanchoco. (2010). Facilities Planning (4th Ed.). New York: Wiley. Identifikasi dan analisis FACILITIES SYSTEM pada suatu perusahaan yang meliputi: Structural Systems Performance Enclosure Systems Atmospheric Systems Lighting and Electrical Systems Life Safety Systems Sanitation Systems Building Automation Systems Facilities Maintenance Management Systems Tugas 39