PLANNING THE STORAGE LAYOUT

A storage area floor plan layout is an excellent management tool in the effective use of space. The floor plan shows the divisions of space into storage, support areas, and aisles. The floor plan also shows the square footage of gross space, nonstorage space, and the net space available for storage.

The required storage space is the key factor in planning warehouses ashore. Several factors are used in computing the required storage space. These factors include the following: l QUANTITY OF INVENTORY. This is the basic part or conversion factor in estimating the required storage space.

l CHARACTERISTICS OF STORAGE FACILITY. This includes storage limitations such as stacking height, floor capacity, structural clearance, and other obstacles.

EQUIPMENT CAPABILITIES. Use of potential warehouse storage height may be restricted by the equipment's inability to reach the full vertical space.

MATERIAL CHARACTERISTICS. The maximum stacking height depends upon the material or its packaging. The material characteristics could cause the stacking height to vary.

TOTAL WAREHOUSE STORAGE SPACE. The gross storage space within a warehouse includes the support spaces, aisles, structural loss, and net storage space.

OCCUPANCY OF NET STORAGE SPACE. Occupying the maximum net storage spare can be hindered by ceiling heights, material characteristics, and "elbow room." Sufficient "elbow room" should be available to minimize relocation to make space for new receipts. Fifteen percent of net available space is considered an adequate allowance for "elbow room" for general supplies.

AISLES. The layout plan must include the aisles to prevent placement-of material in inaccessible areas and loss of space.

MATERIAL FACTORS

Items with similar handling requirements should be stored together when practicable. This will facilitate storing, caring, and moving of material. The fastest moving items should be stored in areas easily accessible to MHE and issue personnel. Loose and unpacked items issue areas should be adjacent to packing and processing areas. Slow moving items should be stored farther from active or processing areas.

DIMENSIONS

The critical factors in developing the layout for storage operations include the relationship between the equipment and warehouse dimensions. Although there are various types and styles of forklift trucks, shelvings, bins, and racks, few conform to predetermined standards. Different makes and styles of forklift trucks require different aisle widths and turning radii. Racks and shelves have different internal dimensions such as column and rail thickness.

OPERATION

Several factors should be considered in planning the layout to support efficient operations. These include handling classification, special handling requirements, pallet rack operations, and small items.

Handling Classifications

There are three basic handling classes of storage in the Navy system. They include the following:

l High cubes and large lots. A limited storage space is needed for bulk or high cube items or large quantity of palletized items.

l Palletized packaged material. These are items of various sires, shapes, and configurations that are _{stored on pallets.} These items include instruments, system components, parts, power tools, and so forth.

l Shelf or bin material. These are small items that can be stored in bins or shelves.

Separation of Elements

Storage spaces used for stowing materials that require special handling need careful planning of _{storage layout.} These are materials that require environmental control, air conditioning, or security and are stored separately from general commodities. Hazardous items should be stored or handled to prevent hazard to personnel and facility. Strict segregation of incompatible materials is mandatory. Incompatible hazardous items, when accidently mixed, could cause fires, explosions, or give off toxic gases. Sensitive items require a high degree of protection and control. Shelf-life items are handled on a first-in, first-out basis.

Pallet Rack Operations

This is the simplest way of handling material. There is no difference in handling a pallet load of batteries or a pallet load of electronic circuit cards. The MHE interfaces with the pallet, and the material on the pallet does not influence the way the material is handled.

Small Items

Small items are materials that can be stored in bins or shelves. In planning the layout, consideration should be given to the shelvings, bins, and MHE. Always consider the number and height of the required shelvings or carousels and MHE such as high rise stock pickers.

MANPOWER

Planning the layout should include a projection of work schedule and manpower requirements of the supply operation. The layout must accommodate the use of MHE and time of manual operations. For example, if two MHEs are needed to accomplish one day's production in a storage area, the transportation aisles should be wide enough to accommodate them. On the other hand, operating in multiple shifts will require reduced equipment requirements and smaller aisle dimensions. Only one MHE, for the use of first and second shift, will be required to accomplish one day's production.

MATERIAL FLOW

Plan the storage layout to ensure an orderly flow of material. The most critical flow area is located where various operations meet and interact. These areas must have balanced throughput and accumulation space to operate efficiently. The flow pattern that you can use is either the cyclic or the straight line flow. The type of flow pattern selected depends upon several factors. These factors include the function of the facility, relationship between receiving and shipping operations, and the relative size, weight, and quantity of material receipts and shipments.

The cyclic flow pattern is useful for low or moderate storage activities. It permits an efficient use of internal material transport system in moving materials. It allows the transport of material from the receiving area to storage, to order picking, and to shipping docks. Figure 2-1 illustrates a typical cyclic-flow pattern.

The straight line flow is used in high activity operations where the material does not go to intermediate storage. The typical application of this pattern is in a high activity freight distribution area. In this case, the activity receives loads of commodities, sorts them by destination, and reloads them to outbound trucks. This flow pattern emphasizes rapid and direct transfer of material from receiving to shipping. Figure 2-2 illustrates a sample straight-line flow pattern.