Lean Sigma Supply Chain » Cheat Sheet

Cheat Sheet – Warehouse Productivity

Lawrence Loucka — Fri, 17 Jul 2009 17:28:07 +0000

Fork-Truck Pallet Movement	Lower Range	Upper Range	Units
Counterbalanced	10	15	pallets/hour
Narrow-aisle Reach	8	20	pallets/hour
Man-up Turret	12	20	pallets/hour
Man-down Turret	15	25	pallets/hour
Narrow-aisle Articulating	8	15	pallets/hour
Stacker Crane	24	30	pallets/hour
Order Picking (Cases)
Pick to cart	25	60	lines/hour
Pick to powered pallet jack	30	80	lines/hour
	50	120	cases/hour
Case pick to conveyor	200	400	cases/hour
Order Picking (Pieces)
Pick to container/conveyor	60	150	lines/hour
Pick to cart	30	100	lines/hour
Carousel to container	200	400	lines/hour
Flow rack to container	100	200	lines/hour
Bin shelves to container	80	150	lines/hour
Truck Load/Unload
Unload floor to conveyor	350	400	cartons/hour
Hand-stack into trailers	150	300	cartons/hour
Palletizing from Conveyor	300	350	cartons/hour
Source: Rules of Thumb, Gross & Associates, 2005 edition

Lawrence Loucka — Thu, 12 Mar 2009 15:26:16 +0000

Material Handling Equipment and aisle widths:

Type	Clear Height	Area to store 1,000 pallets	Aisle width
Counter-Balanced Truck	22′	10,000 sqft	144"
Narrow Aisle Reach	32′	6,270 sqft	90"
Very Narrow Aisle Swing-Reach	32′	5,480 sqft	66"
VNA Double Deep	32′	5,120 sqft	66"
Narrow Aisle Deep- Reach	32′	5,120 sqft	92"
VNA Swing-Reach	40′	3,420 sqft	66"
VNA High Reach Rail Guided	65′	2,020 sqft	56"

Lawrence Loucka — Wed, 11 Mar 2009 16:22:03 +0000

An example from a recent warehouse layout project; analysis leading up to a facility block (zone) layout.

Pallets per Item	No. of Items	Total No. of Pallets	Average No. of Pallets per Item	Floor Stack	Double Deep, Drive In	Push Back	Single Deep	Case Deep	Flow Rack	Shelves	Bin Drawers
>100	2	350	175	x	x	x	o	o
51 to 100	18	1,100	61	x	x	x	o	o
21 to 50	40	1,000	25	x	x	x	x	o
11 to 20	160	2,200	14	o	o	x	x	o
6 to 10	330	2,300	7	o	o	x	x	x
2 to 5	500	1,600	3			o		x
0.5 to 1	750	750	1					x	x
0.25 to 0.49	900	270	0.3					o	x	x
0.001 to 0.25	1,100	65	0.06						x	x	o
< 0.001	200	0.10	0.0005							o	x

X=preferred, O=workable but not preferred