INDEX
Please note that index links point to page beginnings from the print edition. Locations are approximate in e-readers, and you may need to page down one or more times after clicking a link to get to the indexed material.
Note: Page numbers are followed by f and t indicate figure and table, respectively.
A
ABC analysis, 24
ABC curve, 56
Accuracy, 83–89
Activity-based costing, 93, 93f, 94f
Activity paretos, 29f. See also Customer paretos
Activity profiling. See Warehouse activity profiling and data mining
Adjacency optimization, 297–300
Agile manufacturing, 64
AGSRV. See Automated guided storage and retrieval vehicle (AGSRV)
AGV picking cart. See Automated guided vehicle (AGV) picking cart
Airline industry, 122
All-clear aisle lights, 147f
Amazon distribution center, 250f
American Cancer Society’s national logistics center
lift and turn table (manual palletizing), 208f
order-picker truck, 190f
pallet-jack picking, 183f
single-deep pallet racks, 146f
stock picker truck, 236f
two-deep push-back rack, 155f
Amway, 116–117
Argos’ London distribution center, 173f
ASRS. See Automated storage and retrieval system (ASRS)
ASRS-fed case picking tunnel, 197, 197f, 198f
ASRS front-end picking (loop conveyor), 247f
Aurora, 151f
Automated case dispensing, 210–211
Automated clamp layer picking, 213f
Automated downstream sorting, 270–272
Automated guided pallet jack, 184, 185f
Automated guided pallet train, 187f
Automated guided shelving system, 250, 250f
Automated guided storage and retrieval vehicle (AGSRV), 175–176, 177t
Automated guided vehicle (AGV) picking cart, 235f
Automated guided vehicle system, 306f
Automated item dispensing system, 250–252, 253t
Automated pallet handling system, 172–176, 177t
Automated picking and shipping inspection, 342f
Automated receiving inspection, 125, 125f
Automated storage and retrieval system (ASRS), 172–175, 177t
Automated unloading, 123–124, 124f
Automatic communication system, 316, 331–342
Autonomous mobile transporter, 306f
Avon Products, 227f, 251f, 263f, 286
B
Bar code, 319
Bar code “gotcha,” 321–322, 322f
Bar code label, 194
Bar code readers, 322–326
Bar code symbologies, 319–322
Bar code system, 319–326
Batch, sort, and sequence put-away, 131, 131f
Batch picking cart. See Cart picking
Batch wave picking carts, 233f, 234f
Bay matching, 305
Bertelsmann’s book distribution center, 281, 284f, 334f, 335f
Beverage wholesaler’s multi-story distribution center, 138f
BIC finished goods distribution center, 196f
Bin shelving system, 61, 216–220
advantages, 216
bin shelving layout, 219f
bin shelving mezzanine, 220f
corrugated inserts for small-parts picking, 217f
drawbacks, 219
mobile system, 220f
overview, 253t
plastic inserts (small-service-parts picking mezzanine), 218f
typical system, 217f
video game picking, 218f
“Black hat” suppliers, 125
Block stacking, 137–144
honeycombing and lane depth optimization, 141–144
operating rules, 144
overview, 157t
stacking height, 139–141
Boots Pharmacy, 209f, 251f, 320
Boredom, 80
Branch transfers, 120
Broken case picking system, 215–255. See also Case picking system
automated guided shelving system, 250, 250f
automated item dispensing system, 250–252, 253t
bin shelving system, 216–220, 253t
cart picking, 229–235
carton flow rack, 224–228, 253t
economic analysis, 252
horizontal carousel, 241–243, 253t
miniload automated storage/retrieval system, 246–250, 253t
modular storage drawers/cabinets, 219–224, 253t
person-up system, 236–239
picker-to-stock retrieval system, 229–240
picker-to-stock storage system, 216–228
picker-to-stock system, 216–240
RightStore optimization, 252, 254f
robotic item picking, 239, 239f, 240f
stock-to-picker system, 240–250
systems comparison and selection, 252–255
tote picking, 235–236
vertical carousel, 243–245, 253t
Bronze zone, 62
Building clear height, 141
Building cube utilization, 305
Business performance measures. See Warehouse performance, cost, and value measures
C
Calendar-clock profiles, 48–56
day-of-week activity profile, 51, 54f, 55f
hour-of-day activity profile, 56, 57f
month-of-year activity profile, 48–51
week-of-month activity profile, 51, 53f
“Captain Carousels,” 23
overview, 253t
Cart-on-track conveyor, 308f
Cart picking, 229–235
AGV picking cart, 235f
batch picking cart, 233f
batch wave picking carts, 233f, 234f
Caterpillar parts distribution center, 230f
health and beauty aids, 230f
Honda parts distribution center, 229f
light picking cart, 234f
L.L. Bean, 233f
mobile online communication, 229
monorail picking cart, 231f
onboard scales/labeling/computing, 232f
pick face pick-pack cart, 231f
pick-to-light batch picking cart, 232f
Shisheido, 232f
U.S. Defense Logistics Agency, 231f
Carton flow rack, 224–228
Avon Products, 227f
back-to-front movement, 224
carton flow rack pick-to-light, 226f
FIFO, 224
L.L. Bean, 228f
mezzanine picking operation, 228f
Nike’s European Union distribution center, 226f
NTT’s Tokyo logistics center, 225f
overview, 253t
U-shaped picking module, 227f
Verizon’s logistics east coast distribution center, 228f
Carton flow rack pick-to-light, 226f
Carton (tote) picking, 235–236
Case layer picking, 211–213
Case order-increment profile, 39, 41f
Case palletizing system, 203–209
manual palletizing, 205, 207f, 208f
mechanical palletizing, 205, 208f
robotic palletizing, 205, 209f
Case pick-to-conveyor operation. See Zone pick-to-conveyor system
Case picking pallet train, 186f
Case picking system, 181–213. See also Broken case picking system
automated case dispensing, 210–211
layer picking system, 211–213
overview, 182f
pick-to-conveyor. See Zone pick-to-conveyor system
pick-to-pallet system. See Pick-to-order/pallet system
single case, 181. See also Single-case picking system
Case sorting comparison, 205t
Case sorting system, 197–206
comparing the systems, 203, 205t
diverter sorter, 198, 199f, 205t
example sorting system analysis, 203, 206f
manual sorting, 198, 199f, 205t
pop-up sorter, 198, 200, 200f, 205t
surfer sorter, 200, 201f, 202f, 205t
tilt-tray sorter, 202, 203f, 205t
Caterpillar DC Georgia, 165f
Caterpillar parts distribution center, 230f
Ceiling clear height, 141
Charge-back penalties, 124
Chocolate candy company, 6–7
Clamp layer picking, 213f
Coca-Cola distribution center, 5, 212f
Coca-Cola warehouse, 137f, 138f
Code One, 320
Code 16k, 320
Code 49, 320
Color-coding scheme, 129–130
Communication devices, 317f, 331–342
Communication media, 317–331, 317f
Communication system. See Warehouse communication system
Composition profiles, 32–42
Computerized pallet loading system, 205
Consolidation, 3
Contact bar code scanner, 322–323, 323f
Contingency and disaster inventory, 5
Continuous moves, 133
Contract warehouse, 16
Conventional pallet handling system, 160–164, 177t
Conveyor-based mechanical palletizing system, 205, 208f
Conveyor system, 305, 307f, 308f
Counterbalance lift truck, 133, 161–164, 176f, 177t
Counterbalance turret truck, 170f
Crew scheduling system, 122
Cross-dock distribution center, 16
Amway, 116–117
candidates and enablers, 119–120
connecting flights (airline industry), 121
consumer products company, 115f
containerization and communication requirements, 120
defined, 18
K-Mart, 117–118
U-shaped flow, 301
Cross-functionalism, 80
Cube movement, 279t
Cube-movement profile, 59, 60f
Cube-per-order profile, 44, 46f
Customer-facing metrics, 80–92
Customer order composition profiles, 32–42
Customer order profiles, 25, 29f
Customer order volumetric profiles, 42–48
Customer paretos, 28–31
Customer-ready products, 120
Customer service, 2–4
Customization, 3
Customs duties, 8
D
Damage indicators, 83, 87f, 89, 90f
Damaged products, 109
Data mining, 21. See also Warehouse activity profiling and data mining
Datamatrix, 320
Day-of-week (DoW) activity profile, 51, 54f, 55f
Deadheading, 133
Delivery quality compliance, 124–125
Demand, 279t
Demand correlation (DCij), 279t
Demand-correlation profile, 64, 67, 67f
Demand increment, 279t
Demand peaks and valleys, 4
Demand-variability profile, 67, 69f, 70
Digital and real-time warehousing, 316
Digitized voice system, 338–340
Direct primary put-away, 112
Direct put-away, 120–121
Direct secondary put-away, 112
Distribution center, 13, 13f, 16
Distribution center layout. See Warehouse layout optimization
Diverter sorter, 198, 199f, 205t
Dock assignment optimization, 123, 123f
Dock resources, 301
Dock-to-stock time (DST), 89, 92
Double-deep pallet rack, 148–149, 157t
Double-pallet jack, 183–184, 184f
DoW activity profile. See Day-of-week (DoW) activity profile
Downstream sorting, 269–272
Drive-through rack, 151
Driverless automated guided pallet jack, 184, 185f
Driverless counterbalance lift truck, 176f
Drop shipping, 112
DST. See Dock-to-stock time (DST)
Dynamic racking system, 151–156
E
East Coast “Inland Empire,” 7, 10f
Edeka, 340f
80/20 principle, 24
Elimination and simplification of work content, 19
Employee-facing metrics, 79–80, 81f, 82f
Employee turnover, 80, 81f, 82f
End-of-aisle ASRS case picking, 192, 193f, 194f
Environmental families, 280
Expansion/contraction planning, 309–312
Extendable conveyors, 132
F
Facility layout. See Warehouse layout optimization
Facility productivity screen, 98f
Family-mix profiles, 32–34
FIFO. See First in, first out (FIFO)
Fill rate, 2
Financial inventory accuracy, 85f
Finished-goods warehouse, 15, 17f
First in, first out (FIFO)
barrier to productivity improvements, as, 39
block stacking, 137
carton flow rack, 224
pallet flow rack, 152
Floor-loaded loose cartons, 120
Floor loading restrictions, 141
Floor space utilization, 309–312
Floor storage (block stacking), 137–144, 157t
Flow, 76
Flow path, 301–304
Flow rack. See Carton flow rack
Food industry, 114f
Ford Motor Company
horizontal carousel system, 241f
inbound pallet stacking frames, 145f
service parts distribution center, 273–275
Forward pick line, 44
Free-form batch picking, 267, 268f
Free-form picking, 264, 266–267
From-to chart, 285
Fulfillment center, 13f
Full/broken-case mix profile, 34, 36, 37f
Full-carton increments, 42
Full/partial-pallet mix profile, 34, 35f
G
Gantry layer picking system, 212f
Gap analysis
warehouse performance, 102–103, 102f, 104f, 105f
warehouse practices, 103, 106f, 107
Garbage in, garbage out, 109
Golden zoning
basic principle, 281
bin shelving, 278–280
demand-correlation profile, 67
pick density, 279t
popularity-cube-movement profile, 62
Gravity-flow rack, 210
Grocery picking method, 184
H
Half-pallet quantities, 39
Hallmark Cards warehousing complex, 6f
Hand-held bar code scanner, 324f
Hand-held RDT, 333f
Handling-mix profiles, 34–36
Handling steps, 111
Handling-unit inventory profile, 71–72, 73f
Hands-free ring scanner, 325f
Happinet distribution center, 186f, 202f, 332f
Health and beauty aids, 230f, 275f
High adjacency requirements. See Adjacency optimization
High-bay picking area (slow-moving items), 237f, 238f
High-bay space, 305
High-density code, 319
High-level order-picker trucks, 190–191
High-priority put-aways, 132
Historical overview, 12–13, 13f
Hits, 279t
HoD activity profile. See Hour-of-day (HoD) activity profile
Hogenbosch shoe distribution center, 131, 131f
Home delivery distribution center, 16
Home Depot, 7
Honda parts distribution center
batch picking cart, 229f
drive-in racks, 150f
facility layout, 300f
makeover of forecasting process and system, 100–102
pallet-train picking, 186f
push-back racks, 154f
Horizontal carousel, 241–243, 253t
“Hot” put-aways, 132
Hour-of-day (HoD) activity profile, 56, 57f
H.P. Hood’s Winchester dairy plant, 17f
HP distribution center, 238f
Humidity, 141
Hybrid storage/retrieval vehicles, 171–172, 177t
I
Ikea, 7
In-floor conveyors, 124
In-line bar code scanner, 325f
In-line order weight checking (book distribution), 262f
Inaccurate deliveries, 109
Inbound accuracy, 83
Inbound cubing and weighing, 126–130
Inbound dock assignment optimization, 123, 123f
Inbound/outbound transportation order profiles, 25
Inbound pallet RFID tag reader, 328f
Inbound pallet stacking frames, 145f
Industrial vehicles, 305, 306f
Inter-distribution center transfers, 120
Interactive data visualization, 25, 26f
Interactivity material handling equipment, 305–308
Interleaving and continuous moves, 133, 134f
International orders, 7
Inventory accuracy, 83, 85f, 86f, 89f
Inventory accuracy benchmarks, 85f
Inventory counting methods, 85f
Inventory management, 4–5
Inventory paretos, 29f. See also Customer paretos
Inventory profile, 70–73
Item activity profiles, 56–70
cube-movement profile, 59, 60f
demand-correlation profile, 64, 67, 67f
demand-variability profile, 67, 69f, 70
order-completion profile, 62–64, 65f, 66f
popularity-cube-movement profile, 59–62
popularity profile, 56–59
Item-family inventory distribution, 70–71, 70f
Item inventory accuracy, 85f
Item inventory profiles, 29f. See also Inventory profile
Item-order-completion profile, 62–64, 65f, 66f
Item popularity profile, 56–59
Item profiles, 29f
J
Jewelry cross-docking (K-Mart), 117f
Juran, Joseph, 23
K
K-Mart, 117–118
KAO distribution center, 124, 208f, 210f, 213f
L
Labor intensity, 257
Labor productivity, 95
Labor utilization, 95
LAM Research’s San Francisco service center, 220f
Lane depth optimization, 141–144
Last in, first out (LIFO)
double-deep rack, 157t
mobile pallet rack, 157t
pallet-flow rack, 157t
Layer picking system, 211–213
Layer-quantity increments, 36
Layout optimization. See Warehouse layout optimization
Lifeway Christian Resources, 286–288, 335f
Lifeway Christian Resources order-picking layout, 287f
LIFO. See Last in, first out (LIFO)
Lift and turn table, 205, 208f
Lift truck layer picking, 212f
Lift-truck picking, 185, 187, 187f
Lift truck utilization, 301
Light picking cart, 234f
Linear 1D bar code, 319, 319f, 320f
Lines- and cube-per-order grid analysis, 47f
Lines- and cube-per-order profile, 44–48, 49f
Lines-per-order profile, 42–44, 45f
L.L. Bean
batch wave picking carts, 233f
carton-flow-rack bays, 228f
high-level case order picking, 191f
linear bar codes, 321f
reslotting, 286
Location inventory accuracy, 85f
Location sequencing, 131
Long-distance hand-held bar code scanner, 324f
Low-bay space, 305
Low-level order pickers, 188–190
Lumber, 151
M
Magnetic stripes and optical cards (smart cards), 330, 331f
Mainline picking with side trips, 281, 284f
Manual cross-docking, 119, 119f
Manual downstream sorting, 269–270
Manual sorting, 198, 199f, 205t
Manual wave picking, 269, 270f
Marks & Spencer, 328f
Material flow planning, 301–304
Maxicode (UPS), 320
Metrics. See Warehouse performance, cost, and value measures
Metro, 329f
Mezzanine system
bin shelving, 220f
carton flow rack, 228f
Miniload ASRS, 246f
Miniload automated storage/retrieval system, 246–250
Amazon distribution center, 250f
ASRS front-end picking (loop conveyor), 247f
floor space requirements, 246
height and length of system, 246
maintenance requirements, 250
miniload ASRS, 246f
mining maintenance parts, 249f
mobile aisles, 247f
multi-shuttle miniload ASRS, 248f
NASA, 248f
overview, 253t
picking display and batch picking, 249f
sequence of containers, 246
sophisticated system, 248, 250
Mobile pallet rack, 154–156, 157t
Mobile voice-based system, 338–340
Modular spine design, 302–304
Modular storage drawers/cabinets, 61, 219–224
advantages, 219–223
automotive plant storage crib, 221f
high cost/when justifiable, 223–224
maintenance parts, 222f
military parts deployment, 221f
mining maintenance parts, 223f
overview, 253t
picking accuracy, 223
typical configuration, 222f
Monorail picking cart, 231f
Month-of-year (MoY) activity profile, 48–51
Multi-shuttle miniload ASRS, 248f
Multiload counterbalance truck, 162, 164f
N
Narrow-aisle vehicles, 164–168, 177t
Netto
ASRS input-output front end, 173f
end-of-aisle ASRS case picking, 193f, 194f
manual palletizing, 207f
tilt-tray case sorter, 203f
Next-pick director and motion detector, 338f
Nike, 200f
Non-contact bar code scanner, 323–326
Noncompliant products, 109
Nutrisystem, 337f
O
Occupancy versus productivity, 294, 295f
OCR system, 317–319
Omni-channel distribution center, 16
Omnidirectional bar code scanning, 323, 326, 326f
On-hand inventory profile, 70–71
On-site vendor-managed inventories, 7
On-time departures, 89
On-time performance indicators, 89, 91f
On-time put-aways, 89
One-dimensional (1D) linear bar code, 319, 319f, 320f
Operating cost distribution, 258f
Operator-to-supervisor ratio, 80
Optical characters, 317–319
Optimized receiving, 110
Order-completion profile, 62–64, 65f, 66f
Order-completion zones, 62, 280
Order-increment profiles, 36–42
Order-picker trucks, 188–191
Order picking and shipping, 18, 257–289
combine work elements, 261–262
distribution of order picker’s time, 260f
importance, 257
increased requirements, 257–259
optimize issue packs, 259
order picking schemes. See Order picking schemes
pick tour sequencing, 288, 288f, 289f
simplify pick tasks, 259–261, 261t
slotting. See Slotting optimization
Order picking schemes, 262–275
downstream sorting, 269–272
Ford service parts, 273–275
free-form picking, 266–267
overview, 263f
pick from primary, 264
pick from storage, 272–275
progressive order assembly, 268, 268f
Shiseido, 275
single-order picking, 266–267
True Value Hardware, 265–266
Xerox service parts, 265
zone picking. See Zone picking
Otto’s Munich distribution center, 211f
Outbound accuracy, 83
Over-aisle storage, 311f
Over-dock storage, 311f
Over labeled and over coded carton, 322f
Overflow warehouse, 15
Overhead monorail, 307f
Overview (World-Class Warehousing and Material Handling), 19
P
P’s and P’s of profiling, 22–25
participation of profiling, 23
perspectives of profiling, 25
pictures of profiling, 24
pitfalls of profiling, 25
power of profiling, 22–23
preparation of profiling, 22
principal and principle of profiling, 23–24
probity of profiling, 23
purpose of profiling, 23
Pallet cubing stations, 128f
Pallet flow rack, 152, 152f, 153f, 157t
Pallet handling system, 158–176. See also Pallet storage and handling system
AGSRVs, 175–176
ASRS units, 172–175
automated vehicles, 172–176
comparing the systems, 159f, 177t
conventional vehicles, 160–164
counterbalance lift truck, 161–164, 176f
hybrid storage/retrieval vehicles, 171–172
narrow-aisle vehicles, 164–168
side-loading truck, 166–168, 169f
space cost/vehicle cost tradeoff, 164
straddle reach truck, 165–166, 167f
turret truck, 168–170
very narrow-aisle (VNA) vehicles, 168–172
walkie stacker, 160–161
Pallet handling system comparison, 159f, 177t
Pallet jack, 183
Pallet-jack picking, 183–184, 185f
Pallet order-increment distribution, 38f
Pallet RFID tag reader, 329f
Pallet stacking frames, 144, 145f
Pallet stacking system, 137–145
Pallet staging bays, 147f
Pallet storage and handling system, 135–179
handling. See Pallet handling system
overview, 136f
RightStore pallet optimization, 178, 179f
selecting a system, 135, 156–158, 176–179
storage. See Pallet storage system
Pallet storage mode analysis, 156, 158, 158f
Pallet storage system, 135–158. See also Pallet storage and handling system
block stacking, 137–144
double-deep pallet racks, 148–149
drive-in/through racks, 149–151
dynamic racking systems, 151–156
floor storage (block stacking), 137–144
mobile pallet racks, 154–156
overview, 136f
pallet flow racks, 152, 152f, 153f
pallet stacking frames, 144, 145f
pallet stacking systems, 137–145
pallet storage mode analysis, 156, 158, 158f
push-back racks, 152, 154, 154f, 155f
selecting a system, 135, 156–158
single-deep pallet racks, 146–148
static racking systems, 146–151
storage system comparison, 157t
Pallet storage system comparison, 157t
Pallet trains, 185, 186f, 187f
Paperless communication, 315. See also Warehouse communication system
Paralysis by analysis, 25
Pareto, Vilfredo, 23
Pareto distribution, 56
Pareto’s law, 23–24
Pattern recognition algorithms, 22
Payless Shoes’ distribution center, 10f, 312f
PC-equipped mobile receiving cart, 129f
PDF 417, 320
Pen bar code scanner, 323f
Pep Boys’ east coast transload facility, 11f
Performance gap analysis, 102–103, 104f, 105f
Performance measurement. See Warehouse performance, cost, and value measures
Person-up system, 236–239
Physical market presence, 4
Physical safety, 79
Pick and pass, 268
Pick and sort, 262
Pick-by-light, put-to-light (retail stores), 338f
Pick-by-light, put-to-light horizontal carousel picking, 241f
Pick-by-light carton flow picking line, 337f
Pick-by-light carton flow rack facings, 337f
Pick-by-light flow rack, 336f
Pick density, 279t
Pick face pick-pack cart, 231f
Pick-from-primary order picking, 264–272
Pick-from-storage order picking, 272–275
Pick task simplification, 259, 261, 261t
Pick-to-conveyor. See Zone pick-to-conveyor system
Pick-to-light, 335f
Pick-to-light batch picking cart, 232f
Pick-to-order/pallet system, 181, 182–194
advantage/disadvantage, 182f
end-of-aisle ASRS, 192, 193f, 194f
high-level order-picker trucks, 190–191
lift-truck picking, 185, 187, 187f
low-level order pickers, 188–190
order-picker trucks, 188–191
overview, 182f
pallet-jack picking, 183–184, 185f
pallet trains, 185, 186f, 187f
picker-down system, 183–187
picker-to-stock system, 182f, 183–192
picker-up system, 188–192
stock-to-picker system, 192, 193f, 194f
turret truck picking, 191–192
Pick tour sequencing, 239, 288, 288f, 289f
Picker-down system, 183–187
Picker-to-stock retrieval system, 229–240
Picker-to-stock storage system, 216–228
Picker-to-stock (PTS) system
bin shelving system, 216–220, 253t
broken case picking, 216–240
cart picking, 229–235
carton flow rack, 224–228, 253t
high-level order-picker trucks, 190–191
lift-truck picking, 185, 187, 187f
low-level order picker, 188–190
modular storage drawers/cabinets, 219–224, 253t
order-pick trucks, 188–191
pallet-jack picking, 183–184, 185f
pallet trains, 185, 186f, 187f
person-up system, 236–239
picker-down system, 183–187
picker-up system, 188–192
robotic item picking, 239, 239f, 240f
tote picking, 235–236
turret truck picking, 191–192
Picker-up system, 188–192
Picking-activity zones, 281, 284f
Picking cart. See Cart picking
Picking tunnels, 197, 197f, 198f
Picking zone, 264
Plant warehouse, 15
Pop-up sorter, 198, 200, 200f, 205t
Popularity-cube-movement profile, 59–62
Popularity profile, 56–59
Powered pallet roller conveyor, 307f
Practices gap analysis, 103, 106f, 107
Preconfigured-unit load, 39
Prescheduling, 122
Prioritized put-away, 132
Product cube and weight information, 126
Profiling, 22–25. See also Warehouse activity profiling and data mining
Progressive order assembly, 268, 268f
PTS system. See Picker-to-stock (PTS) system
Public warehouse, 16
Purchase order profiles, 25, 29f
Push-back rack, 152, 154, 154f, 155f, 157t
Put-away, 18. See also World-class receiving and put-away
Put-away location verification, 132
Q
Quarter- and half-pallet preparation, 127f
Quarter-pallet quantities, 39
R
Rack-supported ASRS building, 174f
Radio frequency identification (RFID) tags, 326–330
Raw material warehouse, 15, 17f
RDT. See RF data terminal (RDT)
Real-time electronic links, 121
Real-time warehousing, 316
Receiving, 16
Receiving and put-away. See World-class receiving and put-away
Receiving flow optimization, 111–112, 113f
Receiving flows concept plan (Amway), 116f
Receiving inspection, 125
Receiving resources, 121
Receiving scheduling, 121–122
Red, yellow, green (RYG), 76, 79
Repetitive tasks, 80
Reslotting statistics, 285
Response times, 2
Retail distribution center, 16
Retail/grocer/dealer distribution, 44
Retail lines-per-order profile, 45f
Return on investment (ROI), 343, 344f
Returns, 4
RF data terminal (RDT), 331–333
RF-directed put-away operation, 130f
RFID tags, 326–330
RightChain decision support suite, 28f
RightChain scorecard, 77f
RightChain supply-chain logistics model, 2, 2f
RightComms, 19
RightComms warehouse communication system, 343f
RightHouse Activity-based costing, 93, 93f, 94f
RightHouse financial opportunities assessment, 104f
RightHouse practices assessment, 106f
RightHouse principles, 19
RightHouse scoreboard damage performance analysis, 90f
RightHouse scoreboard facility productivity screen, 98f
RightHouse scoreboard on-time performance analysis, 91f
RightHouse scoreboard utilization 360 screen, 99f
RightHouse scorecard summary screen, 78f
RightIns, 19
RightLanes lane depth optimization, 143f
RightPack quarter- and half-pallet preparation, 127f
RightPaths, 19
RightPick, 19
RightPuts, 19
RightShip, 19
RightSlot decision tree, 276f
RightSort analysis (e-fulfillment company), 206f
RightStore, 19
RightStore broken-case picking storage mode optimization, 254f
RightStore eaches optimization, 283f
RightStore pallet optimization, 178, 179f
RightStore pallets optimization, 282f
RightStore preference regions, 255f
RightViews, 19
Rio Tinto vendor management inventory warehouse, 11f
Robotic item picking, 239, 239f, 240f
ROI. See Return on investment (ROI)
Roller-bed trailers, 132
RYG. See Red, yellow, green (RYG)
S
Safety, 79
Safety stock, 2
Savings-to-cost ratio, 285
Schwan’s Food Company, 5
Scroll
mail-order distribution center, 270, 271f
multistory distribution center, 304f
omni-channel distribution center, 132, 132f
slow mover’s warehouse, 155f
Sear’s DC Georgia, 168f
Seasonal inventory, 5
Seasonality activity distribution, 48, 52f
Selective pallet rack, 146
Self-contained warehouse processing cells, 31
Self-directed work team, 80
Separation of the vital few from the trivial many, 23–24
Servant leadership, 76
Shareholder-facing metrics, 92–102
Shinwa, 126–130
Shipping, 18. See also Order picking and shipping
Shipping accuracy, 83, 88f, 89f
Shoe sorter (surfer sorter), 182f, 200, 201f, 202f
Shuttle table, 210
Side-loading truck, 151, 166–168, 169f, 177t
Silver zone, 62
Single-case picking system
automated system, 210–211
pick-to-conveyor system. See Zone pick-to-conveyor system
pick-to-pallet system. See Pick-to-order/pallet system
Single-deep narrow aisle, 157t
Single-deep pallet rack, 146–148, 157t
Single-order picking, 266–267
Sit-down counterbalance lift truck, 161f, 163f
Slotting database, 277–278
Slotting optimization
bin shelving slotting example, 278, 280t
environmental families, 280
follow the map to slot, 281, 284
implement the reslotting program, 286
importance, 276
Lifeway Christian Resources, 286–288
mainline picking with side trips, 281, 284f
omni-channel apparel retailer, 67, 68f
order-completion zones, 280
picking-activity zones, 281, 284f
popularity-cube-movement distribution, 59–62
reslotting statistics, 285
RightSlot decision tree, 276f
slotting, what is it?, 276
slotting database, 277–278
slotting statistics, 278–280
storage-mode families, 280–281, 282f, 283f
10-step slotting methodology, 277–286
Slotting period (R), 279t
Slotting statistics, 278–280
Small-load autonomous mobile transporter, 306f
Small-parts order picking, 216
Small warehouses, 31
Sourcing, 6–8
Space-allocation decisions, 59
Space efficiencies, 309–312
Space productivity, 95
Space requirements planning, 292–297
Special orders, 115
Split case inner packs, 39–42
Stacked linear bar code, 319, 320f
Stacking height, 139–141
Stakeholders, 23
Stand-up counterbalance lift truck, 162f, 163f
Standard deviation of demand (S), 279t
Static racking system, 146–151
Stihl Corporation, 294–297
Stock picker, 190
Stock picker truck, 237f
Stock-to-picker (STP) system
automated guided shelving system, 250, 250f
broken case picking, 240–250
horizontal carousel, 241–243, 253t
miniload automated storage/retrieval system, 246–250, 253t
vertical carousel, 243–245, 253t
Storage, 18
Storage drawers. See Modular storage drawers/cabinets
Storage-environment families, 280
Storage-location utilization, 95, 100, 101f
Storage-mode decisions, 59
Storage-mode families, 280–281, 282f, 283f
Storage requirements optimization, 296f
Storage requirements planning, 292–297
Storage/retrieval system. See Pallet storage and handling system
STP system. See Stock-to-picker (STP) system
Straddle reach truck, 165–166, 167f, 177t
Straddle truck, 164–165, 166f, 177t
Sun Distribution’s third-party logistics center, 119, 119f
Supplier on-time arrivals, 89
Supplier paretos, 29f. See also Customer paretos
Supply chain flows (food industry), 114f
Surfer sorter, 200, 201f, 202f, 205t
Swagelok, 241f
Synthesized voice system, 338–340
T
Task-by-light system, 334–338
Telescoping conveyor, 210, 211
The Home Depot, 7
3d animation model, 27f
Tilt-tray sorter, 202, 203f, 205t
Tote picking, 235–236
Traditional receiving, 112
Transfer orders, 115
Transloading, 11f
Transportation economies of scale, 8
Traveling and documenting, 262
Traveling and extracting, 261–262
Trending indicators, 79
True Value Hardware, 265–266
Turnover (T), 279t
Turret truck picking, 191–192
Two-deep push-back rack, 155f
Two-deep rack facings, 148
Two-dimensional bar code, 319–320
Two-dimensional warehouse simulation, 27f
U
U-shaped flow design, 300f, 301
Unit cube (C), 279t
Unit-load ASRS, 172
U.S. Defense Logistics Agency, 171f, 231f
V
Value-added services, 3
Vehicle lift-height capacity, 141
Vehicle-mounted RDT, 332f
Vendor compliance report, 125
Verizon’s distribution center, 169f, 196f, 228f, 336f
Vertical carousel, 243–245, 253t
Very narrow-aisle (VNA) vehicles, 168–172, 177t
Virtual “heads up” display, 341, 342f
Virtual warehouse, 31
Vision system, 340–341, 341f, 342f
VNA vehicles. See Very narrow-aisle (VNA) vehicles
Voice headsets, 338–340
Volume, 279t
Volumetric profiles, 29f, 42–48
W
Wand bar code scanner, 323f
Warehouse accuracies, 83–89
Warehouse activity profiling and data mining, 21–73
calendar-clock profiles, 48–56. See also Calendar-clock profiles
composition profiles, 32–42
customer order profiles, 25, 29f
customer order volumetric profiles, 42–48
customer paretos, 28–31
defined, 21–22
family-mix profiles, 32–34
handling-mix profiles, 34–36
inventory profile, 70–73
item activity profiles, 56–70. See also Item activity profiles
order-increment profiles, 36–42
overview, 29f
pattern recognition algorithms, 22
profiling, 22–25. See P’s and P’s of profiling
Warehouse activity relationship charting, 297
Warehouse asset utilization, 95, 99–102
Warehouse communication system, 315–344
bar code system, 319–326
communication devices, 317f, 331–342
ergonomics, 343
lights and displays, 334–338
optical characters, 317–319
overview, 317f
return on investment (ROI), 343, 344f
RF data communications, 331–333
RFID tags, 326–330
system selection and justification, 343, 344f
typical system (retail distribution center), 343f
virtual “heads up” display, 341, 342f
vision system, 340–341, 341f, 342f
voice headsets, 338–340
Warehouse communication system justification, 344f
Warehouse cost performance, 93–95, 96f, 97f
Warehouse cube utilization, 100, 101f
Warehouse Data goggles, 342f
Warehouse flow path, 301–304
Warehouse inventory accuracy, 83, 85f, 86f, 89f
Warehouse layout optimization, 291–313
adjacency optimization, 297–300
bay matching, 305
expansion/contraction planning, 309–312
floor space utilization, 309–312
interactivity material handling equipment, 305–308
material flow planning, 301–304
material handling equipment, 305–308
puzzle piecing, 291
seven-step RightPaths methodology, 292
space efficiencies, 309–312
space requirements planning, 292–297
Warehouse order cycle time (WOCT), 92
Warehouse performance, cost, and value measures, 75–107
accuracy, 83–89
customer-facing metrics, 80–92
drilling down, 79
flow, 76
performance gap analysis, 102–103, 104f, 105f
practices gap analysis, 103, 106f, 107
red, yellow, green (RYG), 76, 79
servant leadership, 76
shareholder-facing metrics, 92–102
sum the whole, 79
trending indicators, 79
workforce-facing metrics, 79–80, 81f, 82f
Warehouse performance gap analysis, 102–103, 102f, 104f, 105f
Warehouse performance simulation screen, 105f
Warehouse practices gap analysis, 103, 106f, 107
Warehouse process flow, 17f
Warehouse productivity performance, 95, 98f
Warehouse productivity versus warehouse occupancy, 294, 295f
Warehouse quality index (WQI), 80, 82f, 88f
Warehouse safety, 79
Warehouse space requirements optimization, 293f
Warehouse-within-a-warehouse concept, 31, 31f
Warehouse workforce turnover, 80, 81f, 82f
Warehousing
constraints/challenges, 14
demands on warehouse manager, 14
historical overview, 12–13, 13f
importance, 12
internal activities, 16–18
operating cost distribution, 258f
role of warehouse in logistics chain, 15f
top three priorities, 315
types of warehouses, 15–16
Warehousing fundamentals, 14–18
Weather (humidity), 141
Week-of-month (WoM) activity profile, 51, 53f
“White hat” suppliers, 125
Wire-guided turret truck, 169f
Witt, 242f
WOCT. See Warehouse order cycle time (WOCT)
WoM activity profile. See Week-of-month (WoM) activity profile
Work-in-process warehouse, 15
Workforce-facing metrics, 79–80, 81f, 82f
Workforce turnover, 80, 81f, 82f
World-class receiving and put-away, 109–134
automated receiving inspection, 125, 125f
automated unloading, 123–124, 124f
batch, sort, and sequence put-away, 131, 131f
cross-docking, 114–120
delivery quality compliance, 124–125
direct put-away, 120–121
direct shipping, 112–114
dock assignment optimization, 123, 123f
handling steps, 111
inbound cubing and weighing, 126–130
interleaving and continuous moves, 133, 134f
optimized receiving, 110
prepackaging, 126
prioritized put-away, 132
put-away location verification, 132
receiving flow optimization, 111–112, 113f
receiving scheduling, 121–122
World-Class Warehousing and Material Handling, overview, 19
WQI. See Warehouse quality index (WQI)
X
Xerox’s Chicago service parts distribution center, 220f, 265
Z
Zone pick-to-conveyor system, 194–210
advantage/disadvantage, 181, 194–195
bar-code label, 194
case palletizing, 203–209. See also Case palletizing system
case sorting. See Case sorting system
outbound orders, 195
picking tunnels, 197, 197f, 198f
advantages, 264t
costs and control complexities, 266t
downstream sorting, 269–272
order-completion accountability, 264