Taught on 23 Sep

8/9/2019 Taught on 23 Sep

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See video ‘material-handling system at a power plant’

chaotic storage / random storage

(article) published in may 2011 (ref : http://www.ssi-schaefer.de/blog/en/order-picking/chaotic -storage-amazon/ )

<<How can something be random on purpose? Well, Amazon, the world’s largest online retailer,stores its goods in a chaotic disorder. But only at first glance, because there’s order behind theapparent disarray. It’s called chaotic storage.

How does chaotic storage work?

A warehouse for chaotic storage – sometimes also known as random storage – is basically ashelving system holding the products. So far, it doesn’t differ from a warehouse with fix storagepositions. What makes a chaotic storage system so special is the flow of material. This starts at the

goods-in section: the warehouse staff takes incoming goods to the shelving system, where theyare placed in unoccupied shelf positions. Each shelf space has a unique barcode and every productas well. The staff uses handheld scanners to record the shelf space and the correspondingproduct, thus telling the computer, where the goods are located.

When an incoming order requires these goods to be picked, the computer compiles a picking list.

It then sends order pickers to exactly those shelf spaces where the requested products can be

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http://www.ssi-schaefer.de/blog/en/order-picking/chaotic



found, according to the database. In order to keep this database current, each article that isremoved from the shelf needs to be scanned again.

By the way, chaotic storage does not imply automatic storage. Although it is possible to operate a

chaotic storage system automatically, it is not always the best alternative. Amazon for instance,still needs quite a lot of manpower, because a simulation of the storage processes showed thathiring warehouse staff was more economical than automation.

What are the advantages of chaotic storage?

Chaotic warehouses are much more flexible than conventional ones and can respond to changesin the product range much easier. This reduces the amount of planning, because neither the rangeof products as a whole nor the sales volume of particular goods, need to be known or planned inadvance.

In addition, chaotic storage allows to use the available storage space more efficiently, becausefreed-up space may be refilled immediately. In a storage system with fixed positions on the otherhand, some shelf space is always reserved for certain articles, even if their actual stocks areconsiderably lower.

Chaotic storage is a time saver, not just when stocking up on goods but also during order picking.Incoming goods are simply placed in free spaces on the shelves. The computer will then createpicking lists with optimised routes whenever someone orders products. This way, the distance the

warehouse staff needs to cover is shortened. Furthermore, picking lists at Amazon are not sorted






by order, which means that the picked products have to be combined to shipments in anadditional step.

The amount of training required by new employees is also remarkably lower when using chaotic

storage. It is not necessary for them to memorise the entire warehouse layout or even singlestorage locations. This will allow you to replace staff more easily or hire seasonal workers duringpeak times.

What are the requirements for chaotic storage?

Intuitively, most people would store similar goods together, virtually sorting them according topredefined characteristics. This would place all books in one section of the warehouse and all toysin another section. But that’s not necessary in a chaotic storage system. The products only needto share the most basic requirements with regard to storage (i.e. temperature, humidity). Furthercharacteristics don’t have to be considered. In a chaotic warehouse, all kinds of different articlesmay lie directly next to each other, such as books, toys, sport equipment, electronics, DVDs,

jewellery and digital cameras. Exceptions are made for fast-moving articles, because it wouldn’tbe worth storing them, and those items which are too heavy or bulky for normal storageoperations. Articles like these have to be stored separately. Perishable goods are also not suitablefor chaotic storage.

Needless to say, all the goods have to be barcoded and entered into the database. The same holdstrue for all possible storage spaces. The computer also needs a kind of map of the entire

warehouse, enabling it to compute optimised picking routes.






Chaotic storage is dependant on a reliable warehouse management system. If the computerwould freeze or lose data, warehouse operations would need to be suspended until the problemis solved.

This type of storage is particularly interesting for distribution centres handling a large number ofitems with small stocks each. This usually is the case in the online retail business.

Also, orders with articles from different categories are a common occurrence there, so storingthem according to categories would not yield any advantages. Quite the contrary: the staff atAmazon takes care not to place articles from the same category directly adjacent to each other.This improves order picking accuracy because mix-ups are much less likely.

The term “chaotic storage” is by the way only justified from a human point of view, but is not atall correct from the standpoint of a computer. For a warehouse management software, a chaoticstorage system is nothing more than a sequence of calculations and database operations.>>






Largest warehouses

Pic i : Internal view of the warehouse where Aalsmeer Flower Auction (world’s largest) takesplace. This warehouse, 990,000 m 2 (10.6 million ft 2) in size, is the world’s 3 rd largest building and isworld’s largest building used as a warhouse. Each weekday, 19 million flowers and two millionplants are sold.






Pic ii : Atl logistics center, hongkong is the world’s 2 nd largest warehouse (world’s 13 th largestbuilding), 5.5 L m 2 (6 million ft 2) in size.

See video atl logistics center.asx






Warehousing activities done by 3pl companies

i. kittingcombining W, X, Y and Z into Ax, y, z may be components which by themselves cannot be used by the consumer.example :an indian computer-manufacturer manufacturers cpu’s (w) at his factory in noida (delhi). heimports lcd displays (x) from south korea. these displays arrive by ship and land at madrasport. he purchases keyboards (y) from a manufacturer in bangalore and mouse (z) from ahyderabad-based manufacturer.situation : this company sells its products all over india. mrs shah - a resident of vile parle,

bombay - has booked a desktop model.

Option 1 :bring X, Y and Z to noida. Pack them with X. (This activity is kitting) Despatch the package tocustomer in vile parle by a 2pl or 3pl company.Distances travelled (to the nearest ’00 km) :

X (madras to noida) : 2,200 kmY (bangalore to noida) : 2,400 kmZ (hyderabad to noida) : 1,500 kmW + X + Y + Z (noida to bombay) : 1,400 kmTotal distance travelled : 7,500 km

Option 2 :








ii. packingmanufacturer might analyse his packing activity and might come to a conclusion that

a. he can earn more money by using the area devoted to the packing section, for amanufacturing activity of another type, or

b. he can earn more money by leasing that area out orc. it will be cheaper to carry out this labour-intensive activity far away from the city (inwhich his factory is located) where labour is much cheaper.

Hence, he will then inform his 3pl company to carry out the packing activity and pay thatcompany for doing so.

iii. labelling(reasons same as those for packing)

In short, activities i, ii and iii are activities outsourced by a manufacturer to 3pl company.






do you notice any problem ?











Dock leveller enables the loading personnel to solve the height-difference problem. Such a dockleveller is called pit-d.l. or recessed-d.l. because it sits in a pit / recess beneath the dock floor,behind the dock door.






A dock-leveller (sold by bay equipment company)

see video telescopic dock-leveller

In simple cases, dock plates and dock boards are used. dock plates and dock boards are simplymetal-ramps. Dock plates are usually made of aluminium while dock boards are usually made ofsteel.






A dock plate sold by expresso uk ltd. It is made of aluminium, weighs 17 kg and can handle max

load 600 kg.






A dock board made by copperloy co, having aluminium floor and steel side-curbs. (side curbs

prevent ‘run-off’)






Dock plates / boards have a diamond pattern (embossed) on their upper surfaces, to preventslippage of wheels of the carts / vehicles using them.

A height differential of between 7 and 8 inches generally requires a 6-foot-long (1.8 m) leveller for

an electric pallet-carrier. A height differential of between 17 and 18 inches generally requires a12-foot-long (3.7 m) leveller for a petrol-engine fork-lift.






An ibc for liquids











An IBC for food products






Flexible ibc (fibc)






fibc






FIBCs sold by Waterplex co (of Australia)

• Volume: up to 1,000 litres• All materials are certified as Food Grade•

Filling and Discharge : Top fill and discharge• Two ply PE liquid film + PP fabric outer• Dimensions : 1050 wide x 1050mm long x 970mm high• Valve : PP 2" or 3" UM






what is this ? (another pic below)











Mezzanine

it is a flat surface constructed between the ceiling and a floor. (generally, it covers a part of thefloor, not the entire floor) Thus, it serves as a floor to objects placed on it and as a ceiling to

objects placed below it.In industrial structures / buildings, a mezzanine is generally constructed from modular a steelconstruction systems (angles, beams, floor plates connected by nut&bolts).

a --- modular => the components can fitted to each other in different ways to meet differentneeds. Hence, the components are neutral of the final design of the structure / equipment. (thatis why, using modular kitchen equipment, a kitchen can be implemented in hundreds of designs)






Pallet racksPallets are often placed on racks. This allows for storage of a quantity of pallets more than aquantity had the pallets had been placed simply on the ground.






pallets stored on racks

the above is selective pallet racking (depth of the racks = 1 pallet)






what are these multicolour objects on racks ?








Pallets are placed by forklift on nested carts riding on inclined rails. Each pallet is then pushedback by subsequent pallet loading, exposing the next cart. When removing product, the forklifttakes out the front pallet, allowing the pallets on carts behind it to roll gently to the front of theracking. in short, the nested carts enable easy placement and retrieval of pallets on the racks.






Pic gIn the above pic of 3pallet-deep push-back racking, blue carts hold the rear-most pallets (first in,last out) while the the red carts hold the front-most pallets (last in, first out). The yellow carts holdthe middle pallets.

See videos (2)






what do you think this is ?






Pic a






Pic c






drive-in pallet racking

What is the difference between systems shown in pics a & c ?

Pic a is of single-entry type

Pic c is of double-entry type. In this type, the rack system is stabilized by a beam in the center(blue line).






What do you think this is ?






drive-through pallet racking

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