Cheat Sheet – Warehouse Productivity

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

 

 

 

 

Cheat Sheet – Material Handling Equipment & Aisle Widths

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"

 

Cheat Sheet – Stock Storage Types

 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