The document outlines the design of a warehouse for an automotive industry. It discusses the location of Oragadam in Chennai which is a major automotive hub. The document then covers warehouse layout considerations including storage areas, inbound/outbound operations and value added processes. It describes various storage equipment options and material handling equipment used like conveyors, cranes, forklifts. Barcodes and RFID are also mentioned for identification and control of inventory.

1. GROUP -1
TOPIC : Design a warehouse-Location, Layout,
Storage Equipment , Material Handling
Equipment.

2. GROUP MEMBERS
• VEENA VIKRAMAN : INTRODUCTION
• PRANAV R PAI : LOCATION
• SUDEV M : LAYOUT
• SIDHARTH . E. UNNI : STORAGE EQUIPMENT
• TIMMY JACOB : MHE
• VISHNU M : MHE
• THRINADH : SAFETY
• TITTU JOHN : GREEN WAREHOUSE
• VISHNU B : CONCLUSION

3. INTRODUCTION

4. WAREHOUSE
• A warehouse is a commercial building for storage
of goods. Warehouses are used
by manufacturers, importers, exporters, wholesal
ers, transport businesses, customs, etc. They are
usually large plain buildings in industrial areas of
cities, towns and villages.
• A place where goods are systematically stored.

5. Are you ready to design a warehouse?
WAREHOUSE DEALING WITH “AUTOMOTIVES”

6. AUTOMOTIVE INDUSTRY
• The automotive industry is a wide range of
companies and organizations involved in
the design, development, manufacturing,
marketing, and selling of motor vehicles,
• The automotive industry is global.
• some of them are called automakers.
• It is one of the world's most
important economic sectors by revenue.

7. AUTOMOTIVE INDUSTRY SECTORS
The automotive industry comprises of two distinct
sectors – the manufacturing sector and the retail,
services and repair (RS&R) sector. The automotive
manufacturing sector encompasses the manufacture of
motor vehicles, including:
• cars
• sport utility vehicles (SUVs)
• light commercial vehicles
• buses
• vans
• medium, heavy and special-purpose highway trucks.
The manufacturing sector also includes the
production of motor vehicle bodies and automotive
parts and accessories.

8. The automotive retail, service and repair sector
encompasses:
• vehicle and vehicle parts sales
• vehicle maintenance through regular servicing
• the repair of damaged vehicles
• the supply of aftermarket equipment
• heavy vehicle repair and servicing
• vehicle recycling and disposal
• fuel retailing
• motorsport
• marine
• bicycles
• outdoor power & equipment.

9. LOCATION
PRANAV R PAI
ROLL NO:25
II MBA ITLM

10. • Oragadam is a town and industrial area located
on the outskirts of Chennai, India.
• It is located 55 km Southwest of City near
Sriperumbudur
• Biggest automobile hub in South Asia
• 22 Fortune 500 companies (of which six are
global car manufacturers)
• By 2008, Sriperumbudur had become a special
economic zone with over US$2 billion
investment primarily in the automotive and
electronics sectors.

11. CONNECTIVITY
• Excellent road and rail connectivity
• Proximity to Chennai port
• Strategic location on the Chennai-Bangalore
highway
• Upcoming greenfield airport for Chennai in
Sriperumbudur
• Upcoming Oragadam-Sriperumbudur
Industrial Corridor Road

12. Companies in Oragadam
• Apollo Tyres
• Daimler AG
• Renault–Nissan
• Komatsu
• Royal Enfield
• Ford
• BMW
• Mitsubishi
• Toyota Tsusho India Pvt Ltd
• TT Assembly India Pvt Ltd
• Mindarika Private Limited
• Bosch Electrical Drives India Private Limited
• Global Automotive Research Centre

13. FAVORABLE FACTORS OF SELECTION
• Location of suppliers and manufacturing plants
• Access to transport networks
• Proximity to ports and airports
• Availability of skilled labor
• Transport links for staff
• Availability of funding, grants
• Availability of finance and resources

14. • Availability of telecommunications
• Availability of energy
• Congestion
• Lead times and responsiveness
• Hospitals and Healthcare facilities
• Banks

15. WAREHOUSE LAYOUT
• SUDEV M

16. Warehouse Layout
 A warehouse is a commercial building for storage of goods.
Warehouse are used by manufactures, importers,
exporters, wholesalers.
 The design of a warehouse requires data collection and
analysis of it.
 Needs to know whole product range , number of items per
line, the size and throughput of each product code.
 Design and utilize the space according to fast moving,
medium moving and slow moving items.

17. Primary Functions
The warehouse layout must satisfy these four primary
functions:
 Product storage
 Inbound operations
 Outbound operations
 Value-added processes

18. Areas to concentrate
 Data collection and analysis.
 Ensure that design is suitable for storage equipment and
MHE.
 Facilities for health and safety of staff.
 Provide ergonomic equipment.
 Reduce the amount of movement within the warehouse.

19.  Understand the building regulations and floor loading
requirements.
 Standardize the packaging for movement and storage.
 Flexibility.
Additional Data required
 The number of supplier deliveries per day.
 The average intake together.
 The number of customer deliveries
 The average order size.
 Method for loading and unloading vehicles.

20. Survey of Cranfield University:
 52% warehouse floor area for storage.,
 16% for receiving and despatch.,
 17% pick/pack operation.,
 7% area for value adding services.,
 7% for battery charging or for empty pallets.

21. Layout

22.  The warehouse layout must be depend on the size and
shape of the building, access to it, type of equipment
utilized and operations carried out.
 The most popular warehouse layout tends to be U-flow
shaped warehouse.
 Receiving and despatch are on the same side of the
building for high dock utilization and facilitating cross
docking.
 The fast moving items are closest to the despatch bay for
minimum travel and combine put away and retrieval.

23.  The design influenced by type of pick operations within the
warehouse.
 Separate area for unit pick and value added services.
 The mezzanine floor above despatch and receiving bay.
 The U-flow design enables greater utilization of the loading
bays but can result in congestion if both areas are busy at
time.
 Sortation and consolidation areas and areas for quality
assurance and empty pallets.

24. Storage Space Planning
 Planning the correct amount and type of storage space is
one of the most difficult decisions.
 Based on experience.
Some considerations:
 What are the fast moving , medium moving and slow
moving commodities ?

25. Aisle width :
 A crucial aspect of warehouse layout is aisle width.
 The distance between pallets in adjacent racks.
 The aisle width is determined by turning circle of forklift
truck and size of pallet carried.
 The recommended width of aisles is at least 3feet wider
than the largest equipment to be utilized, or a minimum of
4 feet.

27. STORAGE EQUIPMENTS
• Block Stacking
• Racked Storage
• Wide Aisle Racking
• Double deep Racking
• Narrow Aisle Racking
• Drive in Racking
• Pallet Flow Storage
• Push back Racking
• Mobile Racking

28. BLOCK STACKING

29. RACKED STORAGE

30. WIDE AISLE RACKING

31. DOUBLE DEEP RACKING

32. NARROW AISLE RACKING

33. DRIVE IN RACKING

34. PALLET FLOW RACKING

35. PUSH BACK RACKING

36. MOBILE RACKING

37. SATELLITE/SHUTTLE RACKING

38. M A T E R I A L H A N D L I N G
E Q U P M E N T .
Timmy Jacob Tomes
Vishnu M

40. What is Material Handling?
“Efficient
goods that
short-distance movement of
usually takes place within the
confines of a building such as a plant or
a warehouse or between a building
a transportation agency. ”
and
Material Handling Equipment

41. Material
Movement
Time
Quantity
Space
Handling Dimensions
•
•
•
•

42. Why Material
improves efficiency
Improves productivity
Maximize profits
Competitive edge
Handling?
•
•
•
•

43. Material Handling Equipment
Material handling equipment (MHE) is used
for the movement , storage
,protection, consumption and disposal of
materials within a facility or at a site.
•

44. Types of material handling equipment
•
•
•
•
•
Transport Equipment
Positioning Equipment
Unit Load Formation Equipment
Storage Equipment
Identification and Control Equipment

45. Transport Equipment
These equipment are used to move materials•
from one location to other

46. Conveyers
Equipment used to move materials over a
fixed path between specific points
•

47. conveyers are used
When material is to be moved frequently
between specific points
To move materials over a fixed path
When there is a sufficient flow volume to
justify the fixed conveyor investment
•
•
•

48. Types of Conveyers
• Mainly there are about 20 types of conveyers




Belt conveyers
Chain conveyers
Slat conveyers
Flat belt conveyers

49. Belt conveyor Chain conveyor
Slat conveyor
Flat belt conveyor

50. Cranes
Equipment used to move materials over
variable paths within a restricted area.
•

51. Types of cranes
•
•
•
Jib cranes
Bridge cranes
Stacker cranes

52. Industrial Trucks
Equipment used to move materials over
variable paths, with no restrictions on the area
covered by the movement
•

53. Types of
Hand Truck
Pallet Jack
Walkie Stacker
industrial trucks
•
•
•

54. •
•
Counterbalanced lift truck
Narrow-Aisle reach truck

55. Fork Lifts
equipment in material• most common
handling

56. Unit Load Formation Equipment
• Unit load formation equipment used to
restrict materials so that they maintain their
integrity when handled a single load during
transport and for storage

57. Pallets
Is a flat transport structure that supports goods in a
stable fashion while being lifted by a forklift.
• 48 x 40 in. pallet is used.
• 1200 * 800 mm “Euro-Pallet ” is
the standard pallet.

58. Pallet Boxes
Reusable container used to unitize and protect loose items for
fork/platform truck handling.

59. Identification and Control Equipment
Identification and control equipment is
and communicate the information that
coordinate the flow of materials within
between a facility and its suppliers and
used to collect
is used to
a facility and
customers.

60. Bar Codes
• Unique bar/space patterns represent
alphanumeric characters.
various
• Bar code system consists of bar code label, bar
code scanner, and bar code printer.
Contact bar code scanners use pen or wand to
read labels.
Non-contact bar code scanners include fixed
beam, moving beam, and omni-directional beam.
1-D codes are most common; 2-D codes enable
much greater data storage capability.
•
•
•

61. Bar codes and scanners
Contact Scanner Non contact scanner

62. Radio Frequency (RF) Tag
• A Radio Frequency Identification Tag (RFID tag) is an electronic
tag that exchanges data with a RFID reader through radio waves.
• Most RFID tags are made up of at least two main parts. The first is
an antenna, which receives radio frequency (RF) waves. The second
is an integrated circuit (IC), which is used for processing and storing
data, as well as modulating and demodulating the radio waves
received/sent by the antenna.
• A RFID tag is also known as a RFID chip.

64. Magnetic Stripe
A strip of magnetic material on which information may be stored, as
an electromagnetic process, for automatic reading , decoding, or
recognition by a device detect magnetic variations on the strip.

65. SAFETY AND SECUITY
THRINADH KETHAGANI
MBA-ITLM
1605305028

67. Safety at work has become a major concern of any business.
Safety measures are taken to prevent work-related injuries, illnesses, and
deaths.
when safety procedures are soundly implemented there are major benefits
such as higher employee satisfaction as well as increased productivity.
Equipment downtime is another factor which can be avoided through the
appropriate use of safety procedures.
SAFETY

68. Safety guidelines to keep warehouse safe:
1. Ensure Safety Equipment is Used at all Times
2. Eliminate Any Potential Safety Hazards
3. Always Use Safe Lifting Techniques
4. Provide Training and Refresher Courses
5. Promote Awareness in your Warehouse
6. Fire safety
7. Slips and trips
8. Manual handling
9. Working at height
10. Vehicles

70. WAREHOUSE SECURITY
With many growing businesses, the need to maintain security over
warehouse becomes a primary concern.
You can't afford to have missing product or materials when you're
struggling with order fulfillment.
Your reputation and profit rely on keeping the premises safe.

71. Steps to keeping warehouse secure
1. Require guests to sign in
2. Multiple forms of surveillance
3. Security guards
4. Uniforms and name badges
5. Limited access

72. Green warehouse
TITTU JOHN P

73. Warehouse Energy Management
Systems
By ensuring that equipment is used only
when needed, companies can see savings from:
• Improved operating efficiencies
• Less downtime due to undetected equipment
problems
• Extended equipment life cycle
• Reduction of power draw (much of your bill is
based on the highest peak in a month, even
though it may last only a few minutes)
• Lower costs of environmental compliance

74. Energy-saving Equipment For the
Warehouse
• Companies can reduce electrical demand by
upgrading to energy-efficient equipment that
utilises high-efficiency motors.
• Conveyors, sortation units, can be powered by
high-efficiency motors or high-efficiency
variable-frequency drives.

75. Saving Space Saves on Utilities
• Vertical height
• Conveyors

76. Lighting & Other Energy Saving Tips
• Install sensors
• Increase the use of natural light
• Solar panels
• Movement reduction of forklift

77. Waste management
• Wood, plastic, paper separated and recycled
• Office papers shred and used as packing
material in warehouse
• Incoming cardboards are reused

78. Initiatives to make warehouse
sustainable
• Location
• Better lighting
• Recycling
• Smarter buildings
• Define goals first

79. CONCLUSION
• VISHNU B