Warehouse Design

Task

1. This is a group In-Class assignment, which will be assessed (5%). In your group, you are required to produce a distribution centre design to accommodate the detailed scenario.

Scenario

• Sector - Retail
• Operating hours - 2 shifts, 8 hours a day Mon-Fri, 6.30am - 11.30pm
• Volumes - reasonably constant, seasonal 20% peaks in Apr/May and Oct/Nov.
• Growth - 5% per annum.
• Design timeline - 5 years
• Products - 5,000 SKU's
• 60% Palletized.
• Each SKU has 1 pick location and an average 5 replenishment/storage locations.
• Each pallet is 'Standard US' (40" x 48") built 48 inches high.
• 30% Shelving. Each SKU has an average dimension of 12"x18"x10" and an average quantity holding of 20 items, no replenishment locations.
• 10% Bulk. Each SKU has an average dimension of 5'x6'x8' and an average quantity of 4 items, no replenishment locations.
• Storage:
• Racking - 5 levels high, 96" bay width (2 pallets), and depth is 42" with 8" gap between back-to-back racking
• Shelving - 10 foot high, 48" deep, configurable shelves.
• Office Requirements - 20,000 sq/ft (Management, HR, Clerical, etc.)
• Ceilings - 40 foot clear
• Aisle widths - 10 foot
• Walkway widths - 4 foot
• Mechanical Handling Equipment:
• Pump Jacks - 10
• Single pallet Walkies - 20
• Double pallet Walkies 10
• Forklift Trucks - 15
• Pallet putaway productivity - 15 pallets/hour
• Picking productivity - 30 picks/hour
• Inbound Receipts - 100 floor-loaded containers per week, productivity 15 man-hours per container.
• Outbound Shipping - 200 store shipments per week, productivity 10 man-hours per shipment.
• Trailer Parking in Yard - 100 trailers

• Other space considerations:

• Battery Changing
• Maintenance
• Returns/Inspection area
• Security
• Janitorial
• Staff Changing Rooms
• Washrooms
• Cafeteria
• IT
• Forklift and MHE parking
• Cardboard compactor
• Plastic wrap compactor
• Trash

Report

Expectations are that the report will answer the fundamental question of how many square feet does the DC need to be to accommodate peaks and annual growth over the 5 year design timeline; also, a DC plan should show the layout of the DC to scale with racking, shelving, and other requirements clearly shown with some commentary on why they have been allocated that space.