Boyd, A. H.

English

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Mississippi State University Scholars Junction Proceedings of the Short Course for Seedsmen MAFES (Mississippi Agricultural and Foresty Experiment Station) 4-1-1977 Efficient Warehouse and Materials Handling for Seedsmen A. H. Boyd Follow this and additional works at: https://scholarsjunction.msstate.edu/seedsmen-short-course Recommended Citation Boyd, A. H., "Efficient Warehouse and Materials Handling for Seedsmen" (1977). Proceedings of the Short Course for Seedsmen. 323. https://scholarsjunction.msstate.edu/seedsmen-short-course/323 This Article is brought to you for free and open access by the MAFES (Mississippi Agricultural and Foresty Experiment Station) at Scholars Junction. It has been accepted for inclusion in Proceedings of the Short Course for Seedsmen by an authorized administrator of Scholars Junction. For more information, please contact scholcomm@msstate.libanswers.com. EFFICIENT WAREHOUSING AND MATERIALS HANDLING FOR SEEDSMEN l/ 2/ A. H. Boyd -121 We seedsmen generally have not given sufficient attention to the warehousing phase of our operations. This is true because most seedsmen have grown into the seed business from a very small operation where most records could be maintained by memory. Today, the situation has changed drastically. Seed warehousing is a subject we must study more closely. My comments are directed primarily toward the seedsman handling a small to medium volume who has 11 growing pains 11 with warehousing. There are some special problems associated with seed warehousing that often are not of as much concern to warehousmen handling products other than seed. For example: (1) slow turnover of inventory; (2) Special environmental requirements for seed, such as dehumidification and refrigeration; (3) many lots, varieties, and classes of seed; (4) limited and varible storage life of seed lots. (The warehouseman's precept of first-in, first-out may not apply after seed quality is evaluated); (5) special stacking and arrangements of lots for sampling by seed control and/or certification officials. To increase our expertise in warehousing, l et's consider the ideas of people outside the traditional disciplines of seed technology. Industrial engineers and the Materials Handling Institute are sources of good information. Many of the ideas for this discussion are taken from the publications listed at the end of this article. Warehousing is not onl y a storage problem but also a materials handling system. Receiving, bulk storage , processing and warehousing are parts of the system. Warehousing is often divided into three bas ic steps ; stocking, order pick i ng and shipping. All of these phases of ll Discussion originally presented during the 1976 SSA Annual convention . ~ Associate Agronomist, Seed Technology Laboratory, MAFES. 122 materials handling are important to an efficient product flow through the plant and are funamental to efficient materials handling. The obvious steps for upgrading a handling system are from MANUAL to ME-CHANIZED to AUTOMATED. Two important aspects of upgrading the handling system are: (1) each step up is an exchange of capital investment for labor expense and, (2) with each step up the operation becomes les s flexible. The capacity for the bulk and bag components of storage will vary tremendously depending on the type business operation - wholesale, retail , bul k, bagged, etc. When planning to upgrade or construct new facilities for bulk and bag storage, go to your records for proces-sing/receiving/ shipping to determine how much of each type of storage is necessary. Figure 1 shows a simplified way of determining how and what type storage will be required. In this example, the maxiumum difference between the cumulative bulk receipts and cumulative processing is the total amount of bulk storage that will be required. The maximum dif-ference between the cumul ative processing and/or bag receiving and cumulative shipments gives the total amount of bag storage space re-quired. One large corn processing company has partially solved the problem of periodic use of bag storage by placing portable bins inside a large air conditioned warehouse . These portable or "knock-down" type bulk storage bins hold the shelled corn seed before processing . After emp-tying a given bin, it is dismantled and stacked in another warehouse. The bagged seed is then stored in the vacated area . Each problem must be solved on its own merits because plant layout and materials handling are so closel y related. Maximum utilization of floor space is always desirable. One problem in utilization is called "honeycombing" or lost storage space in front of partial stacks caused by shipment of partial lots or storage of different size lots within the same area (Figure 2). This problem exists in all warehouses to some degree and only careful and constant attention can minimize it. Stacking lots in the warehouse to permit inspection by seed control or seed certification inspectors i s necessary . Figure 3 shows an ex-ample of seed lots stacked in pairs with approximately two feet of space between pairs to allow a walkway on at least two sides of the stacks. This utilizes a smal l amount of warehouse space but eliminates the need for movement after the inspection . Figure 4 is one alternative in whi ch two lots are stacked side by side with space left for a third lot, which is stacked temporarily in the aisle. After sampling, the third lot is restacked into the space to obtain maximum floor utilization. This V) z 0 ..... 5500 5000 4500 4000 3500 3000 2500 2000 1500 1000 500 / / / / / , I . R . /I Cumu atave eceapts / 1 \ / I // IBulk Storage Required // / I I / / I I I I I I I / I I Cumulative Processing I Storage Required I ~I ~ Cumulative Shipments 0 v;= I I I I I Cl I I I I I I I I I I I I I 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 DAYS Figure 1. Bulk and bag storage requi red at any particular time. ..... N w 124 r-0 II> .... II> .... 0 ... 0 <0 CD _.., ... 0 ::::J .... ""0 0 ... ~. 0 n 0 CD a.. :T 0 ::::J CD "'< n 0 3 rr ::::J <0 [n nrl nln n·rl_n_ rl l tl;l r-rl nn nnll ' J l ' I I I i . I ' I· I 'i I . I ll !! I ' l i i l II : : :· I ! ;; I I : l I !I !I ~ ~~J l=J 3J l:_J~ j tJI~__i[s J9J 1_1o_!h :~!j~:J ~~J 1 ~J [~b_jp 7 j ~ ~ i1 r- ~~. - l l li-! ~-·-,r· -·1 !~. !r-j :-~~--: : - ·;··! r--1;--; ~1 .. ;;l IJ II • I ' • I . I· .. . I I I ' ' I' I : ; 1 j, . i ·i. I I . i ·u' 'I 1 . ~ 1 , ! r 1 , : 1 1 ; ; : , 1 ~ 1 , ~ . 1 : . i , , 1 , 1 ! ,,, I i il II II 1,· ll i ; :,! I j ,; : ; :: :. I .1 i l I il 11 I .: i I I ' · I ' I ,: ' I I ! ! i I I • " ' I I ; I . ' . . : I . ' I ! l~. L_;L_j _L~- u~ -~-=-~-=-:::~:.:-= ~---=~~ --'L.; "-_j JJI Figure 3. Example showing how seed lots are stacked in pairs with approximate 2 feet space between pairs to allow space for obtaining samples after lots are stacked in ass igned lanes. N (J1 ......__..._..._ ... . ~ -1.0 N ..-n ~I I L_j nn n ~~ r]ll 12~~15 ~~1 1718 bl~21 ~[:31 n n u Figure 4. Example showing how seed lots are stacked in pairs of lanes with a vacant lane between the pa i rs to all ow room for obtain ing samples for germination . makes the most efficient use of floor space at the expense of a small amount of extra handling . The principal fault of this system is the necessity of restacking when resampling is necessary. 127 Floor space utilization may be enhanced by stacking pallets at an angle instead of at right angles. This permits better space utilization through using more narrow aisles. Figure 5 is an example of this ar-rangement and Figure 6 shows the comparative0advantage of an angular layout over on-the-square placement. The 35 angle placement appears to be the most efficient resulting in0an approximately 14% increase in space utilization. An angle of 10 actually results in a loss rather than a gain in space utilization. Utilization and layout of aisles is very important . Some guide-lines that have been presented for warehouse layout are: (1) keep the aisles straight; (2) use both sides of working aisles; (3) the length and width of aisles should be determined to avoid wasting storage space; (4) use one-way traffic when practical; (5) avoid dead ends in the aisles; Width of aisles will depend upon the system utilized . With two-way traffic and right angle stacking , a 12-foot aisle width is about minimum for most seed warehouses. With one way traffic and angl e stacking, aisles may be reduced to as little as 8-feet.Handl ing equipment and pallet size are also factors affecting efficient utilization of ware-house space. Arrangement of stocks within the warehouse is affected by: (1) product popularity; (2) life of the item stored; (3) the cube per order. Figure 7 is an example of layout by product popularity where the fast moving lots of seed are placed closest to the dock work space, medium movers next and the slow movers furtherest away. Figure 8 is a modifi cation of the same situation where l ots are grouped by kind as, for instance, all corn lots are grouped together with varieties that move fastest stacked closer to loading dock. Another variation of this system could be the location of pick racks near the shipping and re-ceiving dock. Order make-up personnel can make up complicated orders in co N ..-I I I L ___ _ PALLET ANGLE PALLET IN END AREA ---, ~, I I _ ______ _J "CENTER LINE OF AISLE Figure 5 . Angle stacking makes space possible when one-way, narrow aisles are used . ~ w _,J _,J < a.. ~ w 0.. ~ u.. 0 V) Figure 6 . no advantage advantage to angular layout 300 I ~ ~ ... l- -5 ON THE SQUARE PLACEMENT -0 280 +5 260 +10 24Q L---~--~----~~~----~--­o 10 20 30 40 50 60 PALLET ANGLE, DEGREES Comparative Advantage of o n Angular Pollet Layout 0 z > < V) w u < a.. V) ~ ...... N \0 130 ,., ...... . 0" C'< (/)"0 • 0 "0 G>C 0 ....... < QJ _, c-+ ..... c-+ -o'< ., . :::1 c-+ .--....... ,., :::1'"1 \00 3 0 -+)(/) -+,.-t ....... o n., ro CJ .. \0 ro ~ QJQJ II> :::1 =r 0. :::1:3 \0 QJ c-+ c-+ o ro :::1 ., .. ....... QJ 0 ....... • II> ('"') • :X: .. QJ :::1 "0 0. . ....... ..... N::l N\0 I ,. N --i ·:3 ""'-! ~ w I N 0 0 .. 0 , , ..,_ __ ~ ...... _, (/'1 "'0 > () m !nnn ; I l! II I II !! '' j·· I LJLJL L ' i n-4 f:• Scyb=l ! I I Lot 306 fro-~ ' Nj. bog:; --480 \ ij------------------l Ti::ket " ' 201 -300 1 Balance - 180 L Inventory cord r-lnr·-l I I' II 1 I 1: . ' jl· :l,~ I -~ I ., :I . I J_--.:.-:· ~...J - -------~ -Figure 9. Example showing how inventory cards are kept on exact diagram of stacking lanes in warehouse. .....J w .....J 132 SEQUENCE LOCATION ~en en .: c > ·a. '4j a.v · - Q) t5~ POPULARITY LOCATION STOCK GROUPS 1. GROUP 1 GROUP 2 GROUP 3 lw~:t:J Fast [M]Medium [S]Siow 1 M s j s :s r ' I . ,, 2. 3. 1. 2. 3. 1. 2. 3. Figure 8. Popularity location mainta i ned while retaining group cl as -sification. (After A. J. Bri ggs}. 133 the same ma nner that a housewife picks her order from the shelves of a grocery store. Restocking the pick racks is from bay storage as needed. Basical ly, improvement of warehouse efficiency involves three possibi lities: (1) change the arrangement of the destination or l ocations in t he warehouse; (2) change the sequence of operations; (3) change the product mix . Arrangement for effic ient stakcing i s important but i t is doubly important for locating and retrieving lots effici entl y. Many seedsmen have not yet taken the basic step of assigning warehouse area desig-nations or painting traffic lines on the floor. A detailed floor dia-gram of the warehouse showing the location of each stack is as essenti al to inventory control as are traffic markers on the floor. A system of designating areas by letters and specifi c stacks by numbers is an ex-cel lent way of l ocating lots quickly. An example of such a location system i s a typical athletic stadium, i.e., Section B, Row 12, Seat 21. Even drunks usual ly find their designated spot in 50,000 sea t stadi um. Figure 9 shows an example of a floor plan that was developed to aid in lot location and inventory control. It is mounted on the wall of the warehouse office, convenient to the manager and the warehouse foreman. With inventory cards attached to the board, the lot, number of bags, shipping record, and balance-on-hand for each locat ion i s avai lable at a glance. All phases of warehousing discussed are pointed toward one ob-jective; order make-up or order picking. Many warehousemen consider this the most important f unction of the storage activity. Thi s function must move smoothly and rapidly if we are to attain the ultimate ob-jective , efficient delivery of high quality seed at a reasonable pri ce to the proper destination on time and at a profit . Many of the functions of warehousing are completely integrated in most smal l management schemes. However, it is important that we con-sider stocking , order make-up, and shipping as separate entities, at least in our minds, when analzying warehousing problems. At some point, as volume grows, these three functions will be separa ted into actual designation of responsbilities. The exact point when this will be required will be determined by the size of the shipping, receiving, and warehousing operation ; the degree of complexity of such operati ons , and the speed with which it i s necessary to ship seed during t he busy season. Increasingly, seedsmen are required to respond more rapidly to retailers with smaller orders. It is not uncommon for a retailer to 134 order seed from the wholesaler only after he has received a request from the farmer. The seedsman who can respond quickly to such orders with high quality seed is the one who is going to continue to receive this business. References 1. Ackerman, Kenneth B., R. W. Gardner and L. P. Thomas. 1972. Understanding todays distributing center. The Traffic Service Corporation (pub.). Washington, D. C. 2. Apple, James M. 1972. Material handling systems design . The Ronald Press Co. New York. 3. Ballou, R. H. 1964. Pallet layout for optimum space utiliza-tion . Transportation and Distribution Management p. 24- 33 . 4. Balz, H. A. and G. E. Hagemann (eds . ) 1958. The materials handling handbook. The Ronald Press Co . New York. 5. Jenkins, Creed H. 1968 . Modern Warehouse Management. McGraw- Hill Book Company , New York . 6. Marsh, R. H. 1963. Material handling analysis. Proceedings. 1963 Short Course for Seedsmen. Seed Technology Laboratory, Mississippi State University. 7. Reddy , Gaddam P. 1972. Basic considerations in the design of warehouses. M.S. Thesis. Dept. of Industrial Engineering, Mississippi State University . 8. Souza , Francisco. 1976. Design Criteria for seed storage fa-cilities . M.S. Thesis. Dept. of Agronomy-Seed Technology, Mississippi State University. 

Efficient Warehouse and Materials Handling for Seedsmen

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Efficient Warehouse and Materials Handling for Seedsmen

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