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Warehouse Design and Layout

Massey Admin - Thursday, May 13, 2010
Let us look at current ideas on design of your projected warehouse:

1. Concrete wall- typically tilt up style-fast and low cost. Pre-fab metal building are fast and low cost. Both systems are very good.

2. Interior clear height should be 20 feet. This should be the dimension under the bar joist.

3. High density sprinklers located within the bar joists.

4. Fluorescent light fixtures up in your joists, centered over your aisles.

5. Motion detectors to activate your in aisle lighting system.

Warehouse Design: Interior Considerations

Massey Admin - Tuesday, April 20, 2010
Remember, your warehouse structure is no more than a skin around your products stored. It is there to protect the products against the environment and theft.

Design the interior system first, then design the skin.

Some ideas to make your warehouse more green and more functional:

  1. Are roof air vents (to increase airflow) and skylights (to increase natural light) appropriate? Think green, think energy savings.
  2. Are wall panels that are translucent a good idea to increase natural light?
  3. Protect your building columns from damage by using the new plastic column protectors. Much less costly than pouring concrete around your columns for protection.
  4. Concrete floor design: Minimum 6" thickness with a good sub-base. Determine the weight of the products stored per square foot plus the rolling load imposed by the warehouse equipment.

New Warehouse Cost Analysis

Massey Admin - Tuesday, April 06, 2010

When you are considering a new warehouse or new warehousing system you should analyze your cost. In this analysis you should consider the following:

  • Space- New building and land cost vs. the costs of existing building and land.
  • Manpower- Yearly payroll cost of proposed system vs. existing system.
  • Product Damage- Yearly cost, proposed system vs. existing system.
  • Equipment and Maintenance- Yearly cost, proposed system vs. existing system.
  • Utilities and Operating cost- Yearly cost such as lighting, heating, refrigeration and maintenance thereof. Also savings in going green. Proposed versus existing system
  • Inventory- Yearly cost reduced movement of inventory, reduced size of inventory, reduce manpower cost. Proposed vs. existing system
  • Taxes and Interest- Yearly cost, compare with existing taxes with proposed. Compare mortgage interest also.

Total all the above and determine your savings

Dock Door Layout Suggestions

Massey Admin - Monday, March 15, 2010

Dock Doors:

  1. Size of Doors 9’x9’ doors standard around midcontinent area trailers are 13’ 6” x 8’ 6”. This size door allows full access to the entire trailer.
  2. Centerline to Centerline of doors should be 12 to 14 feet, This allows the driver to have enough room to back in the trailer.
  3. Door Considerations: Insulated, non insulated, vertical lift, overhead, power or manual. This all depends on the application.
  4. Door track protection will significantly prolong the life of the door.

Loading Dock Options

Massey Admin - Monday, March 08, 2010

In considering the use of dock levelers:

  1. You can chose mechanical levelers (spring loaded with an upward biased). Operator pulls a chain and walks the leveler down. This is the most economical unit in initial cost, however it has the highest maintenance cost.
  2. You can also choose airbag levelers. Push button operation by the dock operator. The air bag inflates and raises the leveler and positions it on the trailer. Higher initial cost, lower maintenance cost.
  3. You can also choose a hydraulic leveler. Push button operation by the operator, hydraulic pistons raise the leveler and position it on the trailer. Initial cost is the highest but hydraulic levelers or the lowest in maintenance cost.

Remember you must determine the number of loads per day and the number of pallet loads per day. This will allow you to choose the right type of leveler.

Please note: If your rates are low a loose dock plate is probably the best option.

Loading Dock Considerations

Massey Admin - Monday, March 01, 2010

Prior to purchasing and designing a loading dock system you should define your problem. In any dock system you have the following variables:

  1. Product and pallets to be loaded and unloaded: size and weight.
  2. Lift truck, pallet truck: size, capacity, and weight.
  3. Rates: How many pallets to be loaded and unloaded per day.
  4. Rates: how many trucks to be unloaded per day.
  5. Dock height: ?
  6. Truck height: ?

Loading Dock Systems

Massey Admin - Wednesday, February 24, 2010
Initial Parameters for loading docks:

  1. Normal dock height for dry trailers is 48” above grade.
  2. Normal dock height for reefer trucks is 52” above grade.
  3. Normal dock approach in front of dock is 200’ in Missouri the maximum truck length is 75’ long and 8.5’ wide.
  4. Normal dock leveler used is a 25k capacity 72” wide x 96” long. Operating range 12” above and below dock height.

Storage Options

Massey Admin - Monday, February 15, 2010

You can design storage systems as follows:
      1.    Bulk stack product on your floors. In initial cost, this is the most economical solution, but you cannot normally stack over
             2 high.
      2.    Selective rack storage: One deeps plus 12’ aisles equals a storage utilization of 33.7%, aisle space is 67.7%.

      3.    Drive-in rack storage: 2 to 7 deep plus 12’ aisles equals 66.7% storage and 33.7% aisles.

      4.    High rise- Turret Truck or Stacker Crane Systems equals 80% storage and 20% aisles.

There are many variations on the above: push back rack, flow rack, narrow aisle lift trucks (single bay, two deep) Product flow # of line items, rates etc.

Warehouse Design Parameters

Massey Admin - Monday, February 08, 2010

1.   Storage systems design required information:
    a.    Clear height in building
    b.    Aisle width
    c.    Product specs
This information is used to build the warehouse around the storage system.

2.    80% of all storage systems on the midcontinent area are based on the following parameters:
    a.    12’ wide aisles.
    b.    20’ high storage height
    c.    Pallet: 40” x 48”
    d.    Load 2500# per pallet
    e.    Counterbalanced fork lift truck, triple stage mast, and side shifter.

3.   Building column centers 40’. A 40’ dimension provides maximum use of floor space when using a pallet foot print of 48” x 48” and a 12’ aisle. This 40’ centerline to centerline between columns is normal for new roof spans (joists and beams).

Warehouse Initial Layout Considerations

Massey Admin - Tuesday, January 26, 2010

If you are designing a warehouse from scratch, please consider the following:

  • Location of your warehouse as a distribution point: Remember 300 mile maximum radius to ship. LTL and Truck Load rate add too much to product cost.
  • Location of your warehouse on a plot of ground: If possible place your loading dock on the east or south side of the warehouse. This will eliminate most of the weather problems in the northern hemisphere (prevailing winds and weather west to east).

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