Suppose that a warehouse contains eight storage bays. Product enters the rear of the warehouse through a rail dock. Product is picked from the storage locations by an out-and-back selection method and shipped from a truck dock at the front of the building (see the design in Figure 12-6). Each bay can hold 2,500 sq. ft. with product stacked 10 ft. high. Ten products are maintained in the warehouse. The following data have been collected:

(a) Lay out the warehouse using the (1) by-popularity method, (2) the by-cube method, and (3) cube-per-order index method.
(b) To what extent are these methods appropriate when more than one item is picked on a route, and when pickers are zoned to pick only a limited part of the product line on each order?

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Average Number of Daily Orders in Which tem Appears 56 103 Storage Space Individual Product Product Required (sqft) Size (cu. ft.) 500 3,000 1,500 1,700 5,500 1,100 700 2,800 1,300 900 1.5 10.6 27 15 84 2.7 15.0 9.0 6.7 3.3 4.7 35