Warehouse Management : A Complete Guide to Improving Efficiency and Minimizing Costs in the Modern Warehouse

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Format: Paperback
Pub. Date: 2011-07-28
Publisher(s): Kogan Page Ltd
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Summary

Warehouses are an integral part of the modern supply chain, involved in sourcing, producing and distributing goods. However, due to the complexities of warehouse operations they can often be one of the most costly parts of the supply chain. Their efficient management is therefore critical for minimizing cost and contributing to an effective and efficient supply chain. Warehouse Managementprovides a complete guide to best practice in warehouse operations. As well as exploring how to increase warehouse productivity and cost reduction it also includes the latest technological advances being applied to warehouses. The author also addresses the crucial topics of people management, risk, warehouse design and how to operate a third party warehouse. Backed up with numerous case studies that demonstrate how to apply new technology, minimize spending, and create efficient, stream-lined operations, this book is an invaluable resource for warehouse managers, logistics professionals, operations managers and students of logistics

Author Biography

Gwynne Richards has over 25 years' experience in warehouse management and logistics. As well as providing a number of courses on warehouse management for practitioners thought the CILT(UK), he is also a visiting lecturer at the University of Warwick.

Table of Contents

List of figuresp. xii
List of tablesp. xv
Acknowledgementsp. xvii
Introductionp. 1
p. 5
The role of the warehousep. 7
Introductionp. 7
Types of warehouse operationp. 9
Why do we hold stock?p. 14
Supply chain trends affecting warehousesp. 18
The growth of e-fulfilment and its effect on the warehousep. 19
Refrigerated warehouses (by Chris Sturman)p. 20
Materials handling and storage in a temperature-controlled environmentp. 20
Energy management and plant maintenancep. 22
Stock management and housekeepingp. 23
Health and safety issuesp. 24
Transportation issuesp. 24
Summary and conclusionp. 25
Role of the warehouse managerp. 26
Introductionp. 26
Warehouse trade-offsp. 28
The warehouse manager's challengesp. 29
People managementp. 32
Challengesp. 34
Attracting and retaining warehouse employeesp. 37
An ageing and constantly changing workforcep. 37
Operating hoursp. 38
Trainingp. 40
Summary and conclusionp. 40
p. 41
Warehouse processes: receiving and put-awayp. 43
Introductionp. 43
Receivingp. 44
Pre-receiptp. 45
In-handlingp. 50
Preparationp. 50
Offloadingp. 51
Checkingp. 53
Cross dockingp. 55
Recordingp. 56
Quality controlp. 57
Put-awayp. 57
Summary and conclusionp. 58
Warehouse processes: pick preparationp. 59
Introductionp. 59
Preparationp. 60
Warehouse layoutp. 70
Summary and conclusionp. 72
Picking strategies and equipmentp. 73
Introductionp. 73
Picker to goodsp. 75
Goods to pickerp. 78
Automated pickingp. 82
Handling equipmentp. 86
Storage equipmentp. 90
Summary and conclusionp. 98
Order-picking methodsp. 99
Introductionp. 99
Paper pick listsp. 99
Pick by labelp. 100
Pick by voicep. 100
Barcode scanningp. 107
Radio frequency identificationp. 110
Pick by light/pick to lightp. 112
Put to lightp. 114
Comparisonsp. 116
Cost of errorsp. 116
Deciding on type of picking system and equipmentp. 118
Summary and conclusionp. 119
Warehouse processes from replenishment to despatchp. 120
Introductionp. 120
Replenishmentp. 120
Value-adding servicesp. 121
Indirect activitiesp. 122
Stock managementp. 123
Stock or inventory countingp. 125
Cycle counting or perpetual inventory countsp. 125
The count itselfp. 126
Securityp. 127
Returns processingp. 128
Despatchp. 131
Role of the driverp. 133
Summary and conclusionp. 133
p. 135
Warehouse management systemsp. 137
Introductionp. 137
Why does a company need a WMS?p. 138
Choosing a WMSp. 139
The processp. 140
Selecting the right WMSp. 140
What to look for in a systemp. 143
Selecting a partnerp. 145
Before the final decisionp. 146
Implementationp. 146
Software as a servicep. 147
Cloud computingp. 147
Summary and conclusionp. 149
Warehouse layoutp. 150
Introductionp. 150
Data gatheringp. 151
Space calculationsp. 152
Aisle widthp. 158
Other spacep. 159
Warehouse layout examplesp. 159
Finding additional spacep. 161
Summary and conclusionp. 162
Storage and handling equipmentp. 163
Introductionp. 163
Storage equipmentp. 163
Storage optionsp. 165
Very high bay warehousesp. 173
Other storage mediap. 177
Warehouse handling equipmentp. 179
Vertical and horizontal movementp. 183
Automated storage and retrieval systems (AS/RS)p. 187
Specialized equipmentp. 187
Recent technical advancesp. 189
Summary and conclusionp. 191
p. 193
Resourcing a warehousep. 195
Introductionp. 195
Processing activitiesp. 195
Other factorsp. 210
Summary and conclusionp. 211
Warehouse costsp. 212
Introductionp. 212
Types of costsp. 213
Return on investment (ROI)p. 214
Traditional versus activity-based costing systemsp. 216
Charging for shared-user warehouse servicesp. 220
Logistics charging methodsp. 224
Hybridp. 226
Summary and conclusionp. 226
p. 227
Performance managementp. 229
Introductionp. 229
Why do we need to measure?p. 230
What should we be measuring?p. 230
How to choose the right performance measuresp. 235
Traditional productivity measuresp. 236
New performance metricsp. 238
Hard and soft measuresp. 241
Integrated performance modelsp. 242
Benchmarkingp. 243
Balanced scorecardp. 246
Summary and conclusionp. 249
Outsourcingp. 250
Introductionp. 250
The outsourcing decisionp. 252
Core activity/core competencep. 254
Improvement in customer servicep. 254
Cost reductionp. 255
Labour relationsp. 255
Financial strategyp. 255
Flexibilityp. 256
Role of third-party contractorsp. 256
Preparing to outsourcep. 257
Choosing the right partnerp. 258
The transitionp. 261
Managing a third-party relationshipp. 261
Why contracts failp. 261
The future of outsourcingp. 263
Summary and conclusionp. 266
p. 267
Health and safetyp. 269
Introductionp. 269
Risk assessmentsp. 271
Layout and designp. 275
Fire safetyp. 276
Slips and tripsp. 277
Manual handlingp. 277
Working at heightp. 277
Vehiclesp. 278
Forklift trucksp. 279
Warehouse equipment legislationp. 281
First aidp. 281
Summary and conclusionp. 282
The warehouse and the environmentp. 283
Introductionp. 283
Legislationp. 284
Warehouse energy usagep. 284
Energy productionp. 287
The environment and wastep. 288
Packagingp. 289
Palletsp. 291
Stretch wrapp. 291
Cartonsp. 292
Labellingp. 292
Product wastep. 292
Waste disposalp. 292
Hazardous wastep. 292
Forklift trucksp. 293
Summary and conclusionp. 293
p. 295
The warehouse of the futurep. 297
Introductionp. 297
Contextp. 297
Views of the future: the landscapep. 298
Lean warehousingp. 301
Views of the future: the warehousep. 302
Scenario Onep. 304
Scenario Twop. 304
Other advancesp. 306
Summary and conclusionp. 306
Referencesp. 308
Useful websitesp. 312
Glossaryp. 313
Indexp. 317
Table of Contents provided by Ingram. All Rights Reserved.

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