FUNDAMENTALS OF WAREHOUSE MANAGEMENT

MODULE DPL30033
FUNDAMENTALS OF
WAREHOUSE MANAGEMENT

First Series
Noor Hazimah Binti Harun
Nur Hazwani Binti Nerrahim

P To Whom It May Concern:
R
E If you read this module, that
F means you
A
C are interested about warehouse
A management. This module will

help the
Semester 3 students of Diploma

logistics
and supply chain management.

This module suitable for them to
read

and gain knowledge before
attending the

lecture to get an overview in their
lesson.

Hopefully, this module can gain
knowledgeable reader about

warehouse.

Copyright

Published by:
Politeknik Kota Kinabalu
No. 4, Jalan Politeknik,
KKIP Barat, Kota Kinabalu Industrial Park
88460, Kota Kinabalu,
Sabah, Malaysia.

Copyright © Politeknik Kota Kinabalu, Sabah, Malaysia, 2021

e ISBN
First Edition September 2021

All right reserved. The author is responsible for ensuring that
his work does not violate any copyright. Editors and publishers
are not liable for any copyright infringement by the author.
No part of this publication may be reproduced, stored in a
retrieval system or transmitted, in any form or by any means,
electronic, mechanical, photocopying, recording or otherwise,
without the prior permission of Polytechnic Kota Kinabalu,
Sabah, Malaysia.

TABLE OF CONTENTS

OVERVIEW COURSE

CHAPTER 1 : INTRODUCTION OF WAREHOUSE MANAGEMENT 3
3
Definition of warehouse 4
Definition of store 6
The roles of warehouse 9
Elements that are critical components in warehousing 10
Key components warehouse management
The aspects of real estate which need to be considered in warehousing 13
15
CHAPTER 2 : WAREHOUSE OPERATION 15
16
The basic process in warehouse operations
A levels of good packaging 18
Function of packaging 18
Symbols and labelling on packaging 19
20
CHAPTER 3 : WAREHOUSE STORAGE AND MATERIAL HANDLING EQUIPMENT 20
22
The objectives of material handling 26
The key principles of materials handling 31
The factors of equipment selection 32
The used of warehouse storage and equipment 35
The equipment for pallet movement 37
The equipment for pallet stacking/racking 40
The alternatives system for pallet storage
The equipment for non-palletized goods
The storage system for non-palletized goods
The specialized storage system
The specialized equipment
The technical advances

REFERENCE

OVERVIEW COURSE 1

WAREHOUSE MANAGEMENT is an integral part of every logistics
system that plays a vital role in providing the desired level of
customer service at the lowest possible total cost. Warehouse exists
mainly to contribute to manufacturing and distribute efficiency.
Numerous factors should be considered in managing a warehouse
such as operational process and procedures, storage method,
material handling, workforce, Warehouse Management System and
inventory management as well as security and safety factors in
warehousing.

CHAPTER 1:

INTRODUCTION TO
WAREHOUSE MANAGEMENT

“Warehousing is the process of storing physical
goods before they are sold or further
distributed in a dedicated warehouse or
storage facility. Warehouses safely and securely
store products in an organized way to track
where items are located, when they arrived,
how long they have been there, and the
quantity on hand.”

(Christina Lopienski, 2018)

3

What is warehouse ?

A warehouse can be defined as part of a logistics systems which
stores products between the point of origin to the point of being
consumption, while providing information to the management on
the cargo status of the item in storage. It is including all the cargo
such as materials, parts, work in process and finished goods.

All the active handling activities in a warehouse to justify the
existence. A warehouse also can provide the value-added services
like repackaging, relabeling, marshal the shipment, etc. to enhance
the value of consignment. A warehouse also has facilities that are
meant for storage of material at different locations.

They can bridge the time and distance gap between the
production and demand functions and the production facilities of
a firm and the market that it serves. Warehousing is important
because it decouples production from distribution. Because
production and distribution lead times can be different,
warehousing allows firms to carry on their production and
distribution functions separately without disrupting any one of
them based on exigencies of market demand.

What is a store?

Differently, a store is a place where cargo is placed for longer time.
Their primary function is to store the goods safely and no time limit is
indicated. Although its function like warehouse but a store has fewer
handling activities performed at location. There are no value-added
services expected of a store.

4

THE ROLES OF WAREHOUSE

• Products storage
Store large stock of goods from the time of their production or
purchase till their consumption. This is to ensure continuous
production/large scale production. Storage is the physical containment
of merchandise while it is awaiting a demand. The storage methods
depend on the size and quality of the items in inventory and handling
characteristics of the product container.

• Product consolidation
Consolidation-receives and console items from different supplier for a
specific customer. Smaller consignments will consolidate at a
warehouse and subsequently dispatched as a volume shipment.
Consolidation may be in-house or provided by a third party. For
example: It’s combined a different type of product together from
supplier A and B to ship out to one specific user.

• Product cross-docking
Goods enter the warehouse from various supplier and are (ideally
immediately). Transferred to vehicles in the required combinations for
shipment to customer (or to a production plant). Associated with
product assortment or product mixing. The fact that goods move
directly across from the receiving dock to the dispatch dock in the
warehouse. For example: multiple type of product from various type of
supplier are shipping out to specific customer. This is called as product
mixing.

• Product sortation
Process of identifying items on a conveyor system and diverting them
to specific destinations using a variety of devices controlled by task-
specific software. Sortation is applied to different applications
depending upon the product type and the required rate.
Two types of sortation:

- Case Sorter
- Units Sorter

5

• Customer fulfilment
Order fulfilment is the process of receiving goods, then processing and
delivering orders to customers. One of the roles in warehouse is
customer fulfilment order. It is the main goals to make customer
satisfaction. The process starts with a customer placing an order and
ends once they receive it
Types of order fulfilment:

• In house order fulfilment
• Outsourced order fulfilment

• Public support
Public support for revitalization is provided when a business needs to
be revitalized for the benefit of society but cannot be revitalized without
this support. A warehouse as one a public support for community in a
one place as they can boost the job opportunity to community.

Besides, they can enhance the economic growth of the country. In
other hand, facilities from local government also play a role in
warehouse such electricity, water supply, public transport and
infrastructure.

6

ELEMENTS THAT ARE CRITICAL COMPONENTS IN
WAREHOUSING

Space:

The warehouse space is a commodity; its price can show great volatility
with change in demand. By the other words, main function of
warehouse is used to storage inventory and stock. There have 6 area
under space components in warehouse.

a. Loading and unloading areas
Loading and unloading areas, which are normally located outside
the warehouse or incorporated into it, are those that trucks and
vehicles transporting and distributing goods have direct access.
In a well-organized warehouse, it is useful to separate these
activities from the rest of the installation, allowing sufficient space
for loading and unloading. This area can be integrated into the
warehouse or be independent.

b. Reception area
The reception area must be located as independently as possible
from the rest of the warehouse, so that it can be used not just for
receiving goods, but also for quality-control and sorting. Once it
has been ensured that the characteristics and quality of the
delivery received matches those of the products ordered, the
next stage is to determine where to position the load within the
warehouse.
Depending on the type of warehouse, it may or may not be
necessary to transform the units received. If this is necessary, a
suitable area must be established for this function. For example,
it may be necessary to split the pallets that have arrived at
smaller units, remove parts that are strapped together, etc. Given
the impact that accurate checking and, above all, correct
positioning, can have on the future performance of the
warehouse, this area must be as large and as separate as
possible.

7

c. Storage area
A storage area is, strictly speaking, an area used only to store
goods. Goods can be stored in several different ways directly on
the ground but stacked or in blocks or on racking units. The
choice of one or the other will depend above all on the type of
product to be stored, whether it can be stacked, and on the
storage quantity and time.

d. Order picking areas
These areas are not required in all warehouses, only when
outgoing goods must have a configuration or composition that is
different to the one, they entered with, or when they require any
type of modification.
Areas for preparing orders can be integrated into storage areas,
as is the case when picking from rack units. They can also be
separate from storage areas, creating specific picking areas,
generally with automated or semi-automated systems.

e. Dispatch areas
These areas are used for packing orders prepared in the
previously described areas. Even if this packing operation is
unnecessary, this area also can be used for goods that have to be
dispatched and loaded into the delivery or distribution vehicles.

f. Service areas
Part of the warehouse must be assigned to support activities at
the facility, such as general and management offices, changing
rooms, bathrooms, and the area for recharging the batteries of
handling devices.

8

Equipment
Equipment consists of material handling devices, racks and all the
hardware and software used to make warehouse functional. Machines
and equipment are used in warehouses and yards for the safe and
efficient handling of goods and materials in bulk or as separate
smaller units.

These are known as Material Handling Equipment (MHE). They help
to load and unload goods (goods outward – goods inward), move
heavy cargo between locations. Examples of material handling
equipment are forklifts, cranes, pallets, heavy-duty sheets for covering
goods. A warehouse manager must ensure that all MHE are serviced
according to their prescribed service intervals and maintenance
contracts are in place.

People
The most critical component in warehousing is people. The personal
performance of warehouse workers often more the different between
high- and low-quality warehouse. Consists by skilled labor and
unskilled labor.

The warehouse worker’s duties and responsibilities should be
clearly detailed in the job description. Ideally, the job description
should also provide a description of the warehouse, its functions and
the warehouse worker’s expected role.
Some responsibilities include:

▪ Collecting merchandise from the distribution center and
safely transporting materials to the shipping bay.

▪ Receiving and documenting merchandise for delivery or
return.

▪ Keeping an inventory of all merchandise entering or exiting
the warehouse.

▪ Identifying any missing, lost or damaged materials and
immediately notify the supervisor.

▪ Ensuring that all the merchandise is safely and securely
packed and labelled for shipping.

▪ Managing all merchandise with appropriate care.
▪ Assisting with training of newly employed workers.
▪ Scanning labels to ensure products are shipped

to the right destination.

9

KEY COMPONENTS WAREHOUSE MANAGEMENT

a. Communication, Documentation and EDI
b. Packaging and Identification
c. Transportation
d. Accountability
e. Decision making
f. Warehouse auditing
g. Human Resource

10

THE ASPECTS OF REAL ESTATE WHICH NEED TO BE
CONSIDERED IN WAREHOUSING.

Warehouse Location

• Desired consumer base: Determine your customer base and
pinpoint the region that you are trying to serve. Having a
warehouse location that is near your desired consumer base
allows for faster deliveries. Having a warehouse location that is
near your desired consumer base allows for faster deliveries.
When the shipping process is faster and cheaper, the customer
will be happier, and we can make a build trust with a loyal
customer

• Location requirements: Determine a reasonable balance of
distance between the manufacturing location, warehouse storage,
and customer and consider the transportation and shipping. A
location that offers both convenience and proximity to your
customers as well as a carrier service, making the shipping
process easier and faster. Strategically placed location, such as in
ports, airports, and train stops to facilitate the movement of
goods.

• Workforce availability: The demographics of the warehouse
location may be more important than the physical space.
Determine your labor needs. Not every geographic location is able
to provide the desired workforce with the right skills and the right
price. Understanding the workforce is important because it
impacts your company’s employee retention and turnover rates,
fruit. Warehouse without a roof used to store granite, marble, and
productivity, and employee-related costs.

11

Types of warehouse building
Must be built according to the goods that to be stored. Example
chill/cold room suitable for storing frozen goods is perishable such as
fish, meat, sand.

Besides, warehouse roof without walls can be used to store wood
and boards. Moreover, there have differentiate between warehouse
building and the type o warehouse. The warehouse building is an alike
of the shape and design of building.
The types of warehouse :

• General warehouse : General warehouses are best suited
for storing goods that have no environmental requirements.
Perishable foods and some consumer products are not
suitable for these types of warehouses because they’re
sensitive to changes it temperature and humidity.

• Automated warehouse : The robotic systems they support
have evolved rapidly in response to the explosive growth in
e-Commerce and the subsequent consumer demand to
receive their goods quickly.

• Climate controlled warehouse : Climate-controlled
warehouses range from facilities that merely keep workers
comfortable to refrigerated spaces capable of deep-freezing
hundreds of thousands of square feet of perishable goods.

Warehouse Facility
A warehouse facility is the one of real estate that should be
considered in warehousing. The service they offer and the others
facility inside the warehouse itself. The more advanced systems they
use for facility, the easier for worker to handle the movement of
goods in warehouse. Other than that, welfare worker also included to
one of the warehouse facilities

CHAPTER 2:

WAREHOUSE OPERATIONS

Breaking it down, warehouse operations covers
a number of important areas, from the
receiving, organization, fulfillment, and
distribution processes. These areas include
Receiving of goods. Cross-docking of goods.
Organizing and storing inventory.

(Shelly Stazzone,2021)

13

THE BASIC PROCESS IN WAREHOUSE OPERATIONS

a. Receiving
To perform the receiving process properly, the warehouse
should be able to verify that it has received the right product, in
the right quantity, in the right condition, and at the right time.
The act of receiving goods from carrier will involve the
unloading of products from carrier, inspect the cargo if any
damage or broke the product and finally recordkeeping tally
assignment. Failing to do so will have consequent impacts on all
subsequent operations.

b. Put away or transfer
Put-away is the second warehouse process and is the
movement of goods from the receiving dock to the most
optimal warehouse storage location. They also can transfer the
goods to a specific area for value added warehouse activities.
Failing to place goods in their most ideal location can impair the
productivity of warehouse operation.

c. Replenishment and Storage
Replenishment is defined both ready-to-sell inventory as well as
raw materials received from suppliers. Storage is the warehouse
process in which goods are placed into their most appropriate
storage space. When done properly, the storage process fully
maximizes the available space in your warehouse and increases
labor efficiency.

d. Picking and Packing
Picking is the warehouse process that collects products in a
warehouse to fulfil customer orders. Since it is the costliest
process in the warehouse, comprising as much as 55% of the
total operating expense, optimizing this process will allow you
to reduce costs significantly and increase your warehouse
efficiency.

14

Meanwhile, packing is the warehouse process that consolidates
picked items in a sales order and prepares them for shipment
to the customer. One of the primary tasks of packing is to
ensure that damages are minimized from the time items leave
the warehouse.

e. Dispatching
The last act from warehouse which consists of product staging
and physically moving the cargo from the warehouse to the
truck or containers. From a warehouse, the normal documents
used are the tally sheet, the delivery order, packing list and
invoice.

f. Cross-docking
Goods enter the warehouse from various supplier and
immediately transferred to vehicle in the required combinations
for shipment to customer or plantation. Cross docking is when
a container unstuffed and the same time the whole cargo is
stuffed back to a different container. Estimated 75% of food
distribution involves cross docking activities from food supplier
to food retailers.

15

A LEVELS OF GOOD PACKAGING

a. Primary Packaging: The first layer to hold the product.
Usually is the smallest unit of distribution or use and is the
package which is in direct contact with the contents
b. Secondary Packaging: Layer or packaging outside the
primary packaging, perhaps used to group primary packages
together.
c. Tertiary Packaging: packaging used for bulk/ pallet
handling. The main for tertiary packaging are for transport
shipping and movement of goods in warehouse. Palletized for
unit load packs tightly into containers.

FUNCTION OF PACKAGING

a. Protection function to avoid any shock, vibration, damage,
and contamination from outside.

b. Distribution function to help when the products are
distributed to the customer by using the carrier.

c. Sales function to make customer attracted design of
packaging thus encourage them to purchase the product.

d. Information function to display the information
(nutritional value, potential hazards, contents, and
symbols) about product on its packaging or product itself.

e. Use function to ensure safe to carry and protect the
goods depending on the right product.

16

SYMBOLS AND LABELLING ON PACKAGING

The symbols for package handling instructions are internationally
standardized in ISO R/780 (International Organization for
Standardization) and in DIN 55 402 (DIN, German Institute for
Standardization). The symbols must never be omitted as they are
self-explanatory and so overcome language problems in
international transport operations.

CHAPTER 3:

WAREHOUSE STORAGE AND
MATERIAL HANDLING
EQUIPMENT

“One of the most crucial parts of analyzing your
warehouse is determining whether you have
the right warehouse material handling
equipment. Material handling equipment is
mechanical equipment used for the storage,
movement, protection, and control of materials,
goods and products throughout the process of
manufacturing, distribution, consumption, and
disposal.”

(Matt Daniel,2021)

18

THE OBJECTIVES OF MATERIAL HANDLING

1. Minimise cost of material handling.

2. Minimise delays and interruptions by making available the
materials at the point of use at right quantity and at right
time.

3. Increase the productive capacity of the production facilities by
effective utilisation of capacity and enhancing productivity.

4. Safety in material handling through improvement in working
condition.

5. Maximum utilisation of material handling equipment.

6. Prevention of damages to materials.

7. Lower investment in process inventory.

THE KEY PRINCIPLES OF MATERIALS HANDLING

1. Planning principle: All handling activities should be planned.
2. Systems principle: Plan a system integrating as many handling

activities as possible and coordinating the full scope of
operations (receiving, storage, production, inspection,
packing, warehousing, supply and transportation).
3. Space utilization principle: Make optimum use of cubic space.
4. Unit load principle: Increase quantity, size, weight of load
handled.
5. Gravity principle: Utilize gravity to move a material wherever
practicable.
6. Material flow principle: Plan an operation sequence and
equipment arrangement to optimize material flow.
7. Simplification principle: Reduce combine or eliminate
unnecessary movement and/or equipment.

19

THE FACTORS OF EQUIPMENT SELECTION

Selection of Material Handling equipment is an important decision as it
affects both cost and efficiency of handling system. The following factors
are to be considered while selecting material handling equipment.

1. PROPERTIES OF THE MATERIAL

Whether it is solid, liquid or gas, and in what size, shape and weight it is
to be moved, are important considerations and can already lead to a
preliminary elimination from the range of available equipment under
review. Similarly, if a material is fragile, corrosive or toxic this will imply
that certain handling methods and containers will be preferable to
others.

2. LAYOUT AND CHARACTERISTICS OF THE BUILDING

Another restricting factor is the availability of space for handling. Low-
level ceiling may preclude the use of hoists or cranes, and the presence
of supporting columns in awkward places can limit the size of the
material-handling equipment. If the building is multi-storeyed, chutes or
ramps for industrial trucks may be used. Layout itself will indicate the
type of production operation (continuous, intermittent, fixed position or
group) and can indicate some items of equipment that will be more
suitable than others. Floor capacity also helps in selecting the best
material handling equipment.

3. PRODUCTION FLOW

If the flow is constant between two fixed positions that are not likely to
change, fixed equipment such as conveyors or chutes can be
successfully used. If, on the other hand, the flow is not constant and the
direction changes occasionally from one point to another because
several products are being produced simultaneously, moving equipment
such as trucks would be preferable.

4. COST CONSIDERATIONS

Several cost elements need to be taken into consideration when
comparisons are made between various items of equipment that are all
capable of handling the same load. Initial investment and operating and
maintenance costs are the major cost to be considered. By calculating
and comparing the total cost for each of the items of equipment
under consideration, a more rational decision can be
reached on the most appropriate choice.

20

5. NATURE OF OPERATIONS

Selection of equipment also depends on nature of operations like
whether handling is temporary or permanent, whether the flow is
continuous or intermittent and material flow pattern-vertical or
horizontal.

6. ENGINEERING FACTORS

Selection of equipment also depends on engineering factors like door
and ceiling dimensions, floor space, floor conditions and structural
strength.
7. EQUIPMENT RELIABILITY

Reliability of the equipment and supplier reputation and the after-sale
service also plays an important role in selecting material handling
equipment.

THE USED OF WAREHOUSE STORAGE AND EQUIPMENT

1. Pallet movement
2. Pallet storage
3. Pallet racking

THE EQUIPMENT FOR PALLET MOVEMENT

a. Hand pallet truck.
• This is a truck with two forks that will fit into the slots of a

pallet. The forks can be raised slightly by a simple pump action
to lift a pallet off the floor.
• The truck can then be pulled manually, and the pallet
deposited at the required floor location in the warehouse. It is
useful for infrequent movements over short distances.

b. Powered pallet truck.
• This is like the above, except that it is battery-powered.
• The trucks may be pedestrian-controlled or may have a

platform or a seat for the operator to stand or sit on.

c. Lift trucks.
• Lift trucks are commonly used both for

horizontal movement and vertical stacking

21

d. Conveyors
• Conveyors are useful for moving material between two fixed

workstations, either continuously or intermittently. They are
mainly used for continuous or mass production operations
indeed, they are suitable for most operations where the flow is
steady.
• Conveyors may be of various types, with rollers, wheels or
belts to help move the material along: these may be power-
driven or may roll freely.

• The decision to provide conveyors must be taken with care,
since they are usually costly to install; moreover, they are less
flexible and, where two or more converge, it is necessary to
coordinate the speeds at which the two conveyors move.

Conveyors are used:
i. When material is to be moved frequently between

specific points
ii. To move materials over a fixed path
iii. When there is a sufficient flow volume to justify the

fixed conveyor investment

Conveyors can be classified in different ways:

i. Type of product being handled: unit load or bulk load
ii. Location of the conveyor: in-floor, on-floor, or

overhead
iii. Whether loads can accumulate on the conveyor, or no

accumulation is possible

22

THE EQUIPMENT FOR PALLET STACKING/RACKING

STACKER TRUCK

• Most stackers like forklifts, designed with forks that lock into
pallets so that it can raise them off the ground. Once the forks are
locked into the pallet, or the load is stacked on top of the forks,
lifting is achieved using a hydraulic pump or winch.

• In a hydraulic manual stacker, we use a pump-activated lever that
activates a jack to raise the forks off the ground. It is optimized by
high-quality seal kits that also help keep them safe and secure.

• Winch-operated pallet stackers trucks are operated by turning
winches that are attached to either link chains or strong wire
cables. A winch pallet stacker can often lift and lower loads
quicker than the hydraulic variety, and they are fitted with special
brakes to reduce the risk of accidental lowering, giving you
complete control.

Characteristics

• Pallet Stackers reach higher than a standard or even high lift
pallet truck with lifting heights up to 3500mm (3.5m).

• Electric stackers are generally battery powered, charged via
an electrical outlet and are available in semi-electric

SEMI-ELECTRIC HYDRAULIC HAND STACKER

-Electric lift functionality
-1000kg capacity
-Adjustable forks

23

COUNTERBALANCED FORKLIFT TRUCK
• Counterbalance forklift trucks are versatile and can be operated

both indoors and outdoors
• A counterbalanced forklift is in a way, a machine ratio and

proportion , opening like a seesaw
• The counterbalanced are very powerful and useful trucks for

several different environments, lifting a variety of heavy loads.
• Narrow aisle, right angle stacking truck designed for unit load

handling with rack interface.

Characteristics
• A wide range of weights ranging from 1.8T up to 48T. On a

sit-down counterbalanced forklift, the fulcrum or pivot point
is the axle of the front wheels.
• There are a variety of fuel types available to power them .
For example , LPG, Petrol, Diesel and Battery Electric
• Counterbalance forklift add extra versatility to an operation
as they can be fitted with a wide variety of attachment
• There are forks at the front and can drive up close to a load
to pick it up and move it

COUNTERBAANCED FORKLIFT TRUCK

-

24

REACH TRUCK
• Reach forklift operate best inside, in environments such as

warehouse.
• The reach truck provides a range of features to help to do the job.
• The reach truck provides a range of features to help to do the job.

Characteristics
• Primarily designed to pick up loads high in racking or

storage.
• The reach loads that sit up high and can extend to stances

beyond their stabilizing legs
• The reach forklift can be fitted with a camera that shows the

driver what is happening above their head on a video
screen

REACH TRUCK

DOUBLE REACH TRUCK
• Double reach forklift can maintain heavier loads than single reach

forklift, also typically reaching further.
• Only be used on smooth surfaces and are not meant for loading

trucks or for moving material over long distances.
• Double reach forklift are not suited for outdoor

use the double reach are ideal for
high stacking and are extremely
nonenumerable.

25

Characteristics
• Reach double trucks can lift to 30 feet high and are capable

of lifting 2500-4500lbs.
• All models can also be equipped with height indicators,

lasers and camera systems to help operators avoid product
or racking damage and see exactly where their forks are.
• Double reach forklift are meant for racked pallet storage and
can load two pallet loads deep for double racking.

DOUBLE REACH TRUCK

NARROW AISLE TRUCK
• Known as trilateral or bilateral turret trucks
• Minimizing the working aisle width and maximizing the best

possible utilization of bulk storage. Turn into the racking to retrieve
and stack pallets, it does not require any extra clearance between
the floor and pallet rack beams.
• This allows consequently more bays to be built within a given
space.
• Can loads on one side of the aisle or the other as well as in front.

26

Characteristics
• A forward-facing cabin enables it to be driven like a car,

simplifying truck control for any operator.
• A clean vision mast with a tilting function enables superb

visibility of pallets during stacking and retrieval
• Easy battery change system thought rear pull-out design
• An ergonomic and spacious cabin with simple to reach and

easy control and operation of the truck

NARROW AISLE TRUCK

THE ALTERNATIVES SYSTEM FOR PALLET STORAGE

BLOCK STACKING
• Block stacking is a form of palletized storage that does not require

any type of storage equipment, and instead loaded pallets are
placed directly on the floor and built up in stacks to a maximum
stable storage height.
• Floor stacking is extremely space intensive and hence requires
very large areas for storing large quantities of stock.
• Containers are stacked up to 7 containers in height.

27

BLOCK STACKING

RACK STORAGE
• Used for short- or long-term placement of materials, products

and loads in a facility, storage racks hold items in an organized
area.
• It mainly stores items to avoid losing or damage. And handle the
group's operations reasonably and usefully.
• The storage rack has a large load-bearing capacity, and each
layer of the storage rack can carry up to 5000kg
• Convenient access to goods, first-in-first-out, 100% selection
ability, and smooth inventory turnover.

RACK STORAGE

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WIDE AISLE PALLET RACKING
• Unrestricted access to pallets at all time. As the system is made

up of adjustable beams, they can be re-engineered and re-
configured, if necessary. High throughput speed and 5m – 4m
in width.
• Access to all pallets. And requires no specialized equipment.

WIDE AISLE PALLET RACKING

DOUBLE DEEP RACKING WIDE
• More efficient system, which eliminates unnecessary aisles and

increases the use of available space. Double deep pallet
racking systems adapt to any type of unit load.
• As with adjustable pallet racking systems, the assembly and
disassembly process and replacement of components is quick
and simple.
• Saves time and effort in the handling of unit loads, generating
fast stock rotation.
• The design of double deep pallet racking enables its
reconfiguration or extension according to the storage needs
that arise.

DOUBLE DEEP RACKING WIDE

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NARROW AISLE RACKING
• Ultimate space-saving option if warehousing or storage floor

space is limited. It gives teams maximum storage capacity and
allows for quick order-picking and fast accessibility to every
pallet. Total and unrestricted accessibility to individual pallets.
• Optimum configuration for maximum storage, density and
efficiency. Styles of beam: Z shape, Closed Box Beams, and the
environmentally friendly I-Beam.
• Heights: Up to 13.5 meters (in one piece). Bay loads: Up to
30000kg. Compartment loads: Up to 5000kg. Compartment
heights: Up to 3500mm

DRIVE-IN / DRIVE-THROUGH RACKING
• To enter the rack from either side to pick up or pull-out pallets

Drive-In racks provide five- to 10-pallet load spaces like the
double-deep racking.
• The drive-in lanes provide access for the forklift to place and
remove stock. However, the forklift has a limited space to
maneuver, and this increases the time required to place and
remove pallets.
• The drive-in rack is like block stacking as the LIFO principle is
used for pallet retrieval.
• A drive- thru rack is accessible from both sides of the racks.
Pallets can be loaded at one end and retrieved from the other.

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LIVE STORAGE

• Pallet live storage provides dense storage while maintaining
‘first-in, first-out’ stock rotation. Under this system, the first
pallet is placed on an inclined roller conveyor.

• -The pallet rolls forward and is then brought to a halt at the far
end of the conveyor by an automatic braking system.

• -The next pallet is then placed on the conveyor, and this rolls
down until it reaches the first pallet, and so on. When the first
pallet is extracted, the other pallets all roll forward one
position.

PUSH BACK RACKING
• This type of pallet uses the LIFO system. As load is placed,

weight and force pushes back on other loads to create space
for the new load.
• Push-back racking is another form of dense storage system
and has the advantage that each level in the ‘block stack’ can
be accessed individually.
• Push-back racking is typically constructed between three and
six pallets deep.

PALLET MOBILE RACKING
• Most rack systems are a trade-off between storage density and

accessibility to individual pallets.
• This is achieved by basically constructing single-deep

adjustable racking onto powered base frames.
• These frames take the whole weight of the double runs of

racking between aisles and move on wheels along rail lines
embedded into the warehouse floor. The frames are
electrically operated so that an aisle can be created at any
point between the double runs of racking.
• Safety features include photo-electric cells and ‘trip’
mechanisms that stop the racks if there is any obstruction.

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THE EQUIPMENT FOR NON-PALLETIZED GOODS

CRANES

• used particularly for moving very heavy loads (such as metal
bars) within a predetermined area, but may also be used for
lighter loads, for example where items may be just too heavy in
relation to manual handling guidelines.

Equipment types include:

i. Jib cranes. These are used for moving loads within a
restricted area, such as in the vicinity of the
workstation. They comprise an arm that pivots around
a central upright (or wall mounting). An electric hoist
moves along the jib so that loads can be lifted and
moved anywhere within the radius of the jib arm.

ii. Overhead travelling cranes. These are often used in
workshops to move heavy loads anywhere within the
building unit. They normally comprise one or two
beams that span the distance between rails fitted high
on two walls of the building. Each end of the beam(s)
rests on an end carriage that runs on the rails. A trolley
with a hoist travels along the beam(s).

iii. Gantry cranes. These are like overhead-travelling
cranes but have uprights and run-on rails fixed to the
ground. They are therefore commonly used for outdoor
applications; for example, in metal stockyards. Some
gantry cranes are rubber tired, and these can be driven
anywhere in a yard.

CONVEYORS

Conveyor systems are used for moving goods between fixed
points, for holding goods as short-term buffer. Both gravity and
powered conveyors may be used for the movement of goods.
Types of gravity conveyors include chutes, skate-wheel conveyors
and roller conveyors.

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These types of gravity conveyors are normally used for moving
goods short distances, for example chutes may be used for
transferring goods down from a mezzanine floor while mobile
skate-wheel conveyors may be used for vehicle loading and
unloading.

Powered conveyors are normally used for longer distances, and
types include:

i. Belt conveyors. Belt conveyors consist of a continuous
belt running on supporting rollers and are generally
used for lighter loads (eg cartons) than roller
conveyors.

ii. Overhead conveyors. An overhead conveyor consists of
a continuous chain running in an overhead track, with
loads on carriers suspended from the chain.
Applications include order picking in warehouses with a
wide range of SKUs (eg mail order companies).

THE STORAGE SYSTEM FOR NON-PALLETIZED
GOODS

SMALL ITEM STORAGE SYSTEMS

-There is a range of equipment designed for the storage of small
items. Some of these are used in combination, and therefore
standard sizes and modularity are important. Whatever system is
used, it is important that there is a specified location, or locations,
for every SKU. Such example :

MAXI BINs :
• Stacked on top of each
• Part of an integrated storage system
• Hung from a range of louvered panels that can be
rack or wall mounted. Used on shelves to hold
those small parts that would otherwise be difficult
to store in conventional racking
• Used within a picking operation to transport parts
to or from your assembly area.

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LONG LOADS RACKING SYSTEM
• Long loads (such as steel rods, carpets and wooden boards)

are problematic in terms of storage, as most racking systems
cannot accept them (because of the rack uprights). In addition,
conventional handling equipment cannot move them
effectively as very wide aisles would be needed to turn the
loads. Specialist storage and handling equipment is therefore
often used. Such as :

CANTILIVER RACKING
• When you need to store bars, pipes or panels, you

always want quick and easy access.
• This is precisely what cantilever racking was developed

for. It comprises racking uprights and cantilever arms to
safely accommodate long goods of all weight classes and
lengths.
• Optional roll-away protection provides an additional
safeguard for the goods.

HANGING GARMENTS SYSTEM
• These are specialist systems for storing and handling garments

on hangers.
• These systems may be manual in nature or may be highly

automated, with garments being put away to reserve storage
rails and then order picked to customer orders automatically
under computer control.
• These activities are based on overhead conveyor systems
controlling the hanging garments either singly or in batches.

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• The individual garments may be identified by, for example, bar
codes, vision systems or radio frequency identification (RFID)
tags and, based on this information, the garments may be
sorted at the rate of several thousand per hour

Garment Crane

35

THE SPECIALIZED STORAGE SYSTEM

AUTOMATED STORAGE AND RETRIEVAL SYSTEM (AS/RS)

• Automated storage and retrieval systems (AS/RS) provide dense
inventory storage to maximize floor space. Often used for tooling,
components, documents or raw materials storage, vertical carousels are
enclosed on all sides.

• Automatic storage and retrieval system is constructed by high level
stereoscopic racking, automatic stacker or radio shuffles, conveyor
system, warehouse management system and related storage
equipment. Automatic storage to replace the manual picking, which is
faster and save effort.

• In order to improve productivity, the system collects a full pallet from
the racking and deposits it at the front of the aisle prior to collecting
another pallet.

• A miniload is basically an AS/RS for small items. A computer-controlled
crane operates along a central aisle and can access cartons or tote
bins from shelving or racking on either side.

AUTOMATED GUIDED VEHICLE (AGV)

• The automated guided vehicle system (AGVS) performs the same type
of handling function as a mechanized tow tractor with trailer or rider
pallet truck.

• The essential difference is that an AGVS does not require an operator.

• It is automatically routed and positioned at the destination without
operator intervention.

• As well as being used for the movement of pallets, AGVs may be used
for transporting large loads such as car bodies and paper reels. In the
latter case, instead of being fitted with roller conveyors to move the
load, they may have ‘cradled’ belt conveyors to hold the reels and to
move the reels on to and off the AGV.

36

• AGVs are used to transport and load pallets of finished goods directly
into standard, over-the-road trailers without any special dock
equipment. AGVs can pick up pallets from conveyors, racking, or
staging lanes and deliver them into the trailer in the specified loading
pattern.

Mini Load ASRS

AGV

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THE SPECIALIZED EQUIPMENT

EXTENDED FORK

• Fork extended are made for light bulky loads.
• Fork extension save space by allowing for double-deep pallet racks at

each side of an aisle.
• Forklift extenders attach to the regular forks for added lifting capacity

and stability.
• Can make it easier for trucks to handle large and odd shape loads.
• Provide stability and reduce the risk of damage to the load.

CRANE AND BOOM ATTACHMENT

• A crane is the type of machine, generally equipped with a hoist rope,
wire ropes or chains, and sheaves, that can be used both to lift and
lower materials and to move them horizontally.

• The device uses one or more simple machines to create mechanical
advantage and thus move loads beyond the normal capability of a
human.

• Cranes are commonly employed in the transport industry for the
loading and unloading of freight, in the construction industry for the
movement of materials.

• Manufacturing industry for the assembling of heavy equipment

38

DRUM GRIP

• A forklift drum gripper not only transports drums but can lift them for
easier stacking and organizing. To do this, simply attach the drum
gripper to a forklift and secure it with the attached locks.

• A heavy duty Eagle-Grip automatic clamping grabber for handling steel
and plastic drums.

• The clamping mechanisms are completely mechanical without
hydraulic or electrical connections.

• Quick adjustable heads which allowed pickup of various drum heights.

CLAMPS

• A clamps is a fastening device use to hold or secure object tightly
together.

• It can prevent movement or separation through the
application of inward pressures.

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DOUBLE PALLET HANDLER

• Double Pallet Handler sets standards with regard to residual capacity
as this attachment has the best lost load center in its class with
highest stability.

• Double Pallet Handler for heavy duty tasks

• Excellent residual capacity - best lost load center in this class

• Independent sides shift serially

• Optional: independent control of separate fork pairs - adjustment of
opening range to suit different types of pallets.

SIDE LOADING TRUCK

• The side loader trailer is like any other flat bed trailer, but with one
main difference: this trailer comes with two crane mechanisms which
are placed on each end of the trailer chassis.

• Therefore, the side loader trailer is specifically designed for
transportation of cargo containers.

• The two lifting mechanisms on each end, allow the driver or operator
to lift and place a standard ISO container on the trailer.

• The hydraulic cranes are designed to pick up containers directly from
the ground, from railway wagons, or from other vehicles where the
containers are placed.

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THE TECHNICAL ADVANCES

AUTOMATED PALLET SCANNING

• Pallet scanning systems are used to route items to their appropriate
locations. Pallet Scan is an Automated Barcode and Package
recognition system.

• The system scans and takes images of all the barcodes and packages
on the pallets as the vehicle enters the Shed.

• Following the unloading and reloading of the vehicle, the barcodes
and packages on the pallet are again scanned as the vehicle exits the
shed.

• This gives a complete audit trail of those pallets that enter and exit
the shed and therefore determines those pallets left in the shed. The
data provided by the system can be integrated to your Data
Processing or Manifest system.

HYBRID VEHICLE

• With pressure from the environmental sector and a need to reduce
energy consumption within the warehouse, manufacturer are also
looking to alternative energy sources.

• These include the introduction of hybrid vehicles and fuel cells that
are used to power lift trucks in high – throughput warehouse
applications.

FORK BASED SCANNING
• The new fork based scanning process not only results in significant

time saving compared with manual scanning, but reduces the forklift
driver’s workload and ensure low picking error rates.

ELECTRIC LIFT TRUCK
• Hydrogen fuel cells can offer higher productivity in electric lift trucks

because they can be rapidly refueled by operators, eliminating the
need to change, store and maintain batteries. Plus, fuel cells produce
constant voltage, which means there is no battery drop towards the
end of shift.
• A number of trucks are also able to return charge to their batteries
through regenerative lifting and braking

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