Chapter Seven: Warehouse Operations

1. Chapter Seven: Warehouse
Operations
Eng. Mohammed S.
Alghamdi
7.4 RECEIVING AND SHIPPING
OPERATIONS

2. Facility
Planning
Warehouse
Ayman
Aljahdali
Presentation
By:
Warehousing
The True
value..
The Great
benefit..
“The Tube” the most sustainable logistics center
in Europe.

3. Facility
Planning
Warehouse
Shipping
Reserve Storage
and
Pallet Picking
Case
Picking
Broken
Case
Picking
Accumulation, Sortation & Packing
Cross-docking
Direct
putaway
to reserve
Direct
putaway
to primary
Replenishment Replenishment
A schematic representation of the warehouse
material flow
Receiving

4. Facility
Planning
Warehouse
Receiving and Shipping
Operations
• Receiving is collection of activities assuring
quantity and quality of materials.
• Shipping includes packaging and checking
orders for completeness.
• Carriers must be properly considered for these
operations along with the activities of carriers.
• Receiving and shipping begin and end upon
crossing the property line by carriers.
• Both warehouse operations are aimed for the
organization to have:
• High efficient material handling.
• Minimization of damage.
• Good housekeeping.
• A continuous flow without excessive
congestion.

5. Warehouse
Facility
Planning
Goods receiving
process:
•Inbound trucker contacts the warehouse to get a delivery
appointment and provides information about the cargo.
•Warehouse officer verifies the advance shipping notice (ASN)
and
•confirms it with received note by phone from the trucker.
•Trucker arrives and is assigned to a specific receiving door.
•Vehicle is safely secured at dock.
•Seal is inspected and broken in presence of carrier
representative.
•Load is inspected and either accepted or refused.
•Unitized merchandise is unloaded.
•Floor-loaded or loose merchandise is unloaded.
•All unloaded material is staged for count and final inspection.
•Proper disposal is made of carrier damage.

6. • A proper area to stage and spot carriers.
• Dock levelers and locks to facilitate carrier
unloading.
• Sufficient staging area to palletize or
containerize goods.
• Suitable area for ready dispatch goods .
• A good system for orders report generation.
• Accumulate and pack the order.
• Check & prepare the order.
• Settle the customer order.
• Place the carrier at secure dock.
• Prepare dock levelers and locks.
• Load & Dispatch the carrier.
Warehouse
The activities required to ship goods include the
following:
The facility requirements to perform the receiving
activities include the following:
Facility
Planning

7. Facility
Planning
Warehouse
Receiving Door Put way Kit
Assemblies
Replenish&
Count
Optimize
WhseTasks
Reports&
Analytics
Dock
Appointments
YardCheck-
Out
Manifest &
Ship
Stage&
Load
Pick&
Pack
Wave &
Allocate
Inbound Operations:
•Schedule and manage dock appointments.
•Locate to yard and dock doors for yard visibility.
•Receive, cross-dock, and perform value added services.
•Put away to dynamic stock locations.
Inventory Operations:
•Optimize material handling with LPNs & warehouse tasks.
•Replenish and count stock locations.
•Support high volume, automated warehouses.
Outbound Operations:
•Manage trailers with yard locations and dock door
movements.
•Support complex picking & packing.
•Support direct-to-customer fulfillment as well as store
The ideal comprehensive Warehouse execution

8. Warehouse Operations
Facility Planning
Receiving and Shipping
functions
Constraint:
One-side access
R: Receiving
S: Shipping
Dock location Point-of-use Point-of-use Centralize
d
Space between
R and S Not Used Not used Used
The key decision to centralize receiving and shipping depends on many
factors including the nature and the time of the activity as well the
location of access to transportation facilities.

9. Facility
Planning
Receiving and Shipping Principles
It is serving as guidelines for streamlining receiving operations
and intended to simplify the flow of material through the
receiving process and to ensure the minimum work is required In
order.
1-Don’t receive the best receiving is no receiving.
shipping directly by the vendor to the customer
2-Pre-receiving goods in a warehouse transfer simply
mean that the incoming cargo is analyzed and checked
to match the purchase receipt.
3-Cross-dock , the fastest, most productive receiving
process is cross-docking—and the simplest kind of
cross-docking activity is one in which an entire
inbound load is sorted and then reloaded onto
one or more outbound vehicles.
4-Direct putaway is the process of immediately
transporting incoming inventory directly to its
final location in your warehouse. Instead of being
placed in storage, you prepare for delivery as fast
as products arrive.
5-Stage in storage locations If material has to be
staged, the floor space required for staging can
be minimized by providing storage locations for
receiving staging. Storage spaces over dock
doors may be a good option.
6-Preparation the goods for shipping
-Prepackage goods.
-Apply labeling and tags.
-Cube and weigh for storage and transport planning.
7- Sort inbound materials for efficient putaway.
8- Combine putaways and retrievals when possible
This technique is especially geared for pallet storage
and-retrieval operations.
9- Balance the use of resources at receiving by
scheduling carriers and shifting time-consuming
receipts to off-peak hours.
10- Minimize or eliminate walking by flowing inbound
in workstations.

10. Facility
Planning
Warehouse
Shipping Principles
Including direct loading best-practice principles for unitizing and
securing loads, automated loading, and dock management.
1-Select cost- and space-effective handling units.
2-Minimize product damage.
3-Eliminate shipping staging, and direct-load to outbound trailers.
4-Use storage racks to minimize floor-space requirements.
5-Use new system to Improve the management of shipping and
receiving docks.
6-Use small-parcel shipping.

11. Facility
Planning
Warehouse
RECEIVING & SHIPPING SPACE
PLANNING
The steps required for determining space requirements for warehouse
operations are:
 Determine what is to be received and shipped
 Determine the number and type of docks
 Determine the space requirements for receiving and shipping area
within the facility.

12. What is to be received and shipped
1-5: Define what is to be received or shipped.
6: Size of shipment.
7: When the receipts and shipments will occur.
8-9: List the types of carriers.
10-11: Handling methods & time required for
loading/unloading.
Facility
Planning
Warehouse
 Implies information regarding what, when and how much of the
items shipped or received.

13. What is to be received and shipped
Facility
Planning
Warehouse
 Identification of carrier types used for shipping and receiving
including the carrier height width and length also with the
height of the dock.
L
RA
H
ContainerTruck
L
RA
H
Semitrailer,City
L
RA
H
StraightTruck
L
RA
H
RefrigeratedTruck
L
RA
H
Semitrailer,Road
L
RA
BH
FlatbedTruck
Typeof
Vehicle
Truck Dimensions
Overall
Length,
L
Bed
Height,
BH
Overall
Height,
H
Overall
Width,
W
Container 55'–70' 56"–62" 12'–13'6" 96"
Semitrailer,
City 30'–35' 44"–48" 11'–13' 96"
Straight
Truck 15'–35' 36"–48" 11'–12' 96"
Refrigerated 40'–55' 50"–60" 12'–13'6" 96"–102"
Semitrailer,
Road 55'–70' 48"–52" 12'–13'6" 96"–102"
Flatbed 55'–70' 48"–60" – 96"–102"
To determine the dock height, find the midpoint of the bed heights of the expected trucks.
Most trucks require a dock height of between 46 and 52 in.
See the Table for dock heights that create level docks for common types of trucks.
Type ofTruck Dock Height
Container 55 in.
Semitrailer 48 in.
Straight Truck 44 in.
Refrigerated 52 in.
Flatbed 52 in.
The dimensions of common truck
and trailer designs

14. Facility
Planning
Warehouse
Waiting line analysis helps determines the number & type
of docks.
If the arrival and service distribution are not much varied
over time then waiting line analysis helps addressing the
problems of number.
If the arrival and service distribution vary over time then
simulation technique will be used.
By type of dock we mean configuration, which has to be
determined after determining the no. of docks.
It considers the flow of carriers relative to the facility.
For rail docks configuration of the railroad spur dictate
the flow of railroads thus leading to configuration of rail
dock
For truck docks traffic patterns of trucks must be
analyzed
Determine the Number and Type of Docks
Waiting line
analysis

15. Warehouse
Receiving and Shipping Docks
 Central Dock (single dock for both receiving and
shipping)
Common equipment and personnel
Better space utilization
Higher incidence of space congestion
Greater risk of material loss
Error in material flow direction, e.g. shipping out a newly-
received part by mistake
 Point-of-use Dock (multiple docks for receiving or
shipping)
Dedicated function, e.g. receiving frequent deliveries from
light-duty carriers or shipping specific category of goods
Often used to support Just-in-Time (JIT) manufacturing
set-ups
Usually requires more space than central docking
Facility
Planning

16. Facility
Planning
Warehouse
90° Dock
Docks are among the first requirements at a site and are vital for smooth
operations.
Dock width that is commonly adopted is 12 feet.
For highly busy docks, width of 14 feet is employed.
Requires greater apron space but less bay
width
Larger outside turning area for carriers
Commonly used when outside space is
sufficient
Warehouse Dock Configurations: 90° Dock

17. Facility
Planning
Warehouse
Requires lesser apron space but more bay width
Bigger inside maneuvering area for carriers
Used when there is insufficient apron space to support 90o dock
The largest finger dock angle possible should be selected
Finger Dock (Sawtooth)
Warehouse Dock Configurations: Finger Dock
(Sawtooth)

18. Facility
Planning
Warehouse
Plan On-site Traffic
Patterns
Design the traffic patterns around the building so
that the truck driver is on the inside of each
turn, for best control of the truck.
Truck movement
counterclockwise.
Efficient truck traffic :
• An entrance driveway that
accommodates the turning radius of the
longest truck expected and allows
trucks to be driven forward onto the
site, rather than backed up.
• Right-angle turns onto the site that
have a minimum inside radius of 26 ft
and a minimum outside radius of 50 ft.
• One-way access roads that are 13 ft wide
minimum.
• Two-way access roads that are 26 ft wide
minimum.
• Separate roads for employee traffic.
• Truck waiting areas near the loading docks to
accommodate all waiting trucks.

19. Facility
Planning
Warehouse
Apron space is the space between the loading platform and the
nearest obstruction.
which is the area the truck uses to maneuver in and out of the
parking area.
The recommended center distance between dock positions is 12 ft
minimum.
Design the Apron
Space

20. Warehouse
Determining shipping area requirement
Receiving and shipping department area requirements within
a facility may include space allocations for the following:
 Personnel convenience/office
 A receiving hold area
 Trash disposal and recycling
bins
 Palletizing equipment
 The truckers lounge
 Buffer or staging areas
 Material handling
Facility
Planning

21. Warehouse
Facility
Planning
Dock operation planning deals with equipment requirements for
shipping and receiving which comprise of equipment suitable between
carriers and docks.The equipment are:
Dock levers (Between a dock at given height and carriers of
variable height)
Bumper pads (Between a fixed dock and a movable carrier)
Dock shelters (Between a heated dock and unheated carrier)
Dock Operations Planning
Dock leveler
A dock leveler is a fixed bridge designed to permit the safe
and efficient flow of goods into and out of a building. In
order to accomplish this, a dock leveler must be able to
support extremely heavy loads, service a wide range of
truck heights, and compensate for tilted trucks.
There two basic types of dock levelers based on
the method of activation.

22. Warehouse
Facility
Planning
Dock Operations Planning
Dock bumpers
Each dock must be equipped with a form of dock bumper to
protect the building from vehicle impact damage.
Keep in mind that an approaching vehicle can generate up to
300,000 lbs. of impact force.
Several styles of bumper are available to suit application
requirements.
For typical level approach applications, bumper projection
should be specified at not less than 4".
The two most common styles of bumpers are molded rubber
and laminated rubber.

23. Warehouse
Facility
Planning
Dock Operations Planning
Vehicle restrictions
In a busy shipping area, there can be up to 100 opportunities
per day, per single loading dock, for the most serious forklift
accident to occur.
It happens at the best of loading docks.
 Vehicle creep.
 Unscheduled truck departures.
 Careless parking.The most common style of vehicle restraint is a face-mount
design.
Face mount restraints have four main functions:
 Prevent premature trailer departure.
 Limit trailer creep away from the dock.
 Restrict trailer movement to keep the extended lip of the
dock leveler in place on the floor of the trailer.
 Prevents trailer theft.

24. Dock shelter
The purpose of installing dock seals or shelters is to maintain the
internal climate of the facility and protect against product
damage.
Use of these products has many benefits such as:
 Energy Loss Savings - Reduces heating and cooling costs by
maintaining interior temperature control.
 Safe Working Conditions - Keeps weather out; eliminates
rain, ice and snow from loading areas, improving dock
safety.
 Merchandise Protection - Protects valuable products against
damaging heat, cold, rain, snow and wind. Minimizes vermin
entry.Warehouse
Facility
Planning
Dock Operations
Planning

25. Facility
Planning
Warehouse
DOCK LOCATIONS
Shipping docks and receiving docks can be combined, with shipping and
receiving together (Figure 1), or they can be separated, with shipping
and receiving in different areas of the building (Figure 2).
 Choose the loading dock location based on the
needs of the in-plant process.
 A combined dock works well in smaller buildings
where shipping and receiving is infrequent.
 However, this design may increase in-plant
traffic and travel distance.
 A separated dock works well in buildings where
the materials enter production in one part of the
building and the production is completed
elsewhere.
 This design minimizes transportation of
materials inside the building

26. Facility
Planning
Warehouse
finally
The Quality Of Your Work, in the Long Run, is the
deciding factor on how much Your Services are valued
by the WORLD.
Orison Swett Marden
Thank
you