Warehousing Operations

1. Receiving

Receiving is the first warehouse process and one of the most crucial. To perform the receiving process
properly, the warehouse should be able to verify that it has received the right product, in the right
quantity, in the right condition, and at the right time. Failing to do so will have consequent impacts on
all subsequent operations

Receiving also involves the transfer of responsibility for the goods to the warehouse. This places
accountability on the warehouse for maintaining the condition of the goods until they are shipped.
Properly receiving cargo will allow you to filter out damaged goods and avoid liability for them.

2. Put-Away

Put-away is the second warehouse process and is the movement of goods from the receiving dock to
the most optimal warehouse storage location. Failing to place goods in their most ideal location can
impair the productivity of warehouse operation. When goods are put away properly, there are several
benefits:

• Cargo is stored faster and more efficiently

• Travel time is minimized
• Safety of goods and employees is ensured
• Warehouse space utilization is maximized
• Cargo is easier and faster to find, track, and retrieve

3. Storage

Storage is the warehouse process in which goods are placed into their most appropriate storage space.
When done properly, the storage process fully maximizes the available space in your warehouse and
increases labor efficiency.

4. Picking

Picking is the warehouse process that collects products in a warehouse to fulfill customer orders. Since
it is the costliest process in the warehouse, comprising as much as 55% of the total operating expense,
optimizing this process will allow you to reduce costs significantly and increase your warehouse
efficiency. Streamlining of this process should also focus on achieving higher accuracy, as errors can
have a direct impact on your customer satisfaction.

5. Packing

Packing is the warehouse process that consolidates picked items in a sales order and prepares them
for shipment to the customer. One of the primary tasks of packing is to ensure that damages are
minimized from the time items leave the warehouse. Additionally, packaging must be light enough so
as not to increase the weight of the goods and minimal enough to control packaging costs.

6. Shipping

Shipping is the final warehouse process and the start of the journey of goods from the warehouse to
the customer. Shipping is considered successful only if the right order is sorted and loaded, is
dispatched to the right customer, travels through the right transit mode, and is delivered safely and
on time. Previous processes, such as ordering, putaway, picking, and packing, are also vital to the
success of shipping because they greatly affect whether the order is fulfilled accurately and safely.
7. Returns Management

This is something most companies wish will just disappear! However, returns are an intricate part of
most businesses, and alas, the volume of returns is growing for many organisations – mainly due to
the e-commerce revolution. Alarmingly, most return orders for many firms is for just one item at a
time.

The complexity around handling returns mandates the following rules:

• When customers return goods, they should seek, and be given Return Management
Authorization, which outlines what is being returned and why.
• All returns must be traceable, to their order, document and invoice.
• Companies must have a pre-determined returns process that delineates what is to be done
with the goods once received back into the warehouse, e.g. return to stock, repair, destroy,
discard, recycle, return to manufacturer, etc.
• All credits must be system-recorded together with reasons why the goods are returned.
• Inventory must be updated where goods are returned to stock, or held for further action.

8. Value-Adding

This is the part of the business where products are produced, kitted, assembled, relabelled, modified,
‘burnt in’, or subjected to some other value-adding process. The value adding part is about performing
work on the product to make it ‘ready for sale’.

This process of value-adding can be complex, particularly when many different items are combined to
form a new product. Complexity around handling value-adding processes and the changing nature of
component products in and out of shelf locations can be daunting.

Over the years, systems have evolved to assist, yet there are many companies that find recording of
value-adding components may be incompatible with how the logistics system or conventional ERP or
WMS have been set up.

Measuring Warehouse Productivity

Warehouse productivity is a measurement of how well you manage this conflict, together with factors
like on-time delivery and warehouse utilization.

Warehouse management has a lot to do with balancing two competing needs: speed and accuracy. If
you manage a warehouse, you typically want your people to work as quickly as possible without
injuring themselves or causing damage to products. At the same time, if you achieve speed at the cost
of accuracy, your business will experience customer complaints and costly restocking and re-delivery
procedures.

1. Order Picking Accuracy (percent by order)

This metric shows how accurately warehouse employees pick products for orders. Order picking
accuracy can drop with multi-part orders, where the employee has to pick products from multiple
bins. The metric is also a measure of the quality of order picking instructions. For example, if the order
says “Product X,” but the employee finds two bins, each with Product X in a different color, this creates
a problem. He or she can take a guess at what color is needed, and then have the company suffer the
consequences of a return. Or, the employee can send the order back for confirmation, which creates
churn and delay.
2. Average Warehouse Capacity Used

A warehouse is a financial asset. As a result, its rate of capacity utilization is an important number for
senior management. If a company is only using 10% of its warehouse capacity, that’s a problem. It
means they’re paying for the rent and upkeep of unproductive space. This may seem like an easy-to-
spot problem, but with multiple sites and changing seasonal inventories, it can be difficult to measure
accurately without the right software and procedures.

3. Peak Warehouse Capacity Used

It’s also helpful to know your peak warehouse capacity utilization. The number itself can be revealing,
like if it’s too low. But, unless its 100%, then there’s room for improvement. Peak warehouse capacity
used is a target, a basis for doing better. If the number was 70% last year, then maybe this year, it
could be 75%

4. On-time Shipments

Shipments reaching customers on-time is a critical success metric for warehouses. It’s important on
its own, because it reflects if the warehouse doing its job right. However, late shipments also create
hidden costs and difficulties elsewhere in the business. They cause customer service calls and
complaints. They cause package tracking and other wastes of time. Ultimately, late shipments can
damage your brand and cause customers to defect.

5. Inventory Count Accuracy by Location

Are the inventory counts accurate in each location? This is another stealth issue that is more important
than it looks. If there are fewer items in a bin than the system says there should be, that might indicate
theft or unreported damage. The results of miscounted inventory include unforeseen stockouts and
fulfillment problems that negatively customer attitudes.

Warehouse Security Control

Inventory shrinkage, cargo theft, lost inventory—whatever you call it, the loss or theft of valuable
inventory in your warehouse can be a big problem.

The Importance of Warehouse Security

A lack of warehouse security gives thieves an easy way to steal product and make a quick buck—and
no ecommerce business is immune to theft. If your customers are willing to buy the product, then it
has a value thieves can capitalize on.

Protecting the Facility Inside and Out

When it comes to warehouse security, it’s important to protect the facility both inside and out.
External-facing warehouse security systems, called perimeter security, are used to defend entry
points, parking lots, and the property line. These external security measures are useful for preventing
theft by keeping thieves out of the warehouse or by intimidating casual thieves into thinking the theft
attempt isn’t worth the effort and risk.

Internal warehouse security measures help to catch thieves who breach external warehouse security
or employees who abuse their access to steal product from the warehouse. Instead of prevention and
intimidation, internal security measures often focus on limiting access or capturing evidence to help
catch thieves after the fact.
What are some of the specific types of warehouse security measures that are needed to create a high-
security warehouse? Some examples of useful warehouse security tools include:

Warehouse Security Cameras. Security camera warehouse setups can be both a great deterrent to
thieves and a simple way to gather strong evidence to pursue a case against them if they do steal
something. Modern security camera systems can collect high-definition footage and upload it to an
offsite server to make identification of thieves easier and preserve the evidence if they try to tamper
with the cameras or onsite recording stations.

Warehouse Lighting. Yes, lighting can be considered a vital part of warehouse security. Poorly-lit
warehouses not only provide protection for thieves (making them harder to identify), they can be a
safety hazard for warehouse employees and security staff. So, keeping warehouse facilities well-lit is
a crucial safety measure—both to prevent theft and on-site accidents.

Alarm Systems. Alarm systems can be a crucial tool for deterring theft attempts, minimizing the
amount of goods stolen by thieves, and summoning security or police in time to stop thieves from
getting away. Knowing that there’s an alarm keeps thieves on a tight time limit so they don’t steal as
much (or deterring them from the attempt). Getting an alert from a silent alarm helps security and
police arrive on the scene quickly so thieves can be detained before they make off with valuable
products.

Security Patrols. Does the warehouse have on-site security staff to help deter thieves? Do they make
the rounds to verify that there are no intruders lurking in security camera blind spots? Having manual
security patrols to police the premises can be a massive deterrent to casual thieves and trespassers
that minimizes large-scale theft risks.

Access Control Systems and Security Cages. How is high-value merchandise kept secure within the
warehouse? How is access to these items controlled? Security cages and access control systems make
it harder for thieves to get at valuable inventory—creating a high-security warehouse environment
that minimizes theft risks.

Inventory Tracking. How is inventory in the warehouse tracked? How frequently is inventory checked
for missing products? Inventory tracking solutions are vital for ensuring that inventory shrinkage can
be identified quickly (and that inventory availability reports in your ecommerce store are accurate).
Keeping track of inventory is a loss prevention 101 basic.

Entryway Security Doors. How tough are the doors allowing entry into the warehouse to bypass?
Weak locks or doors can allow thieves into the warehouse quickly, giving them easy access to the
interior. Robust doorways delay thieves, increasing the likelihood of them getting caught by
police/security (and of them giving up before making entry).

Window Security. Are there ground-level windows that thieves can easily break to get into the
warehouse? Or, are they high up and reinforced to prevent break-in and entry? Strong security means
making windows as difficult to break into as possible, such as using reinforced glass, window locking
mechanisms, or even steel bars/window covers to deter entry attempts.

Ways to Improve Warehouse Security

Upgrade Your Security Measures. Looking at the list from the “Types of Warehouse Security
Measures” section, how many of them is your warehouse currently using? Do you have the budget to
upgrade these measures or to add new ones? Taking a look at the security measures list and filling in
any significant gaps can go a long way towards improving your facility’s overall security.
Use Remote Camera Footage Backups. If you have security cameras, it can be well worth your while
to subscribe to a service that backs up your security footage in real time for offsite storage. This way,
if thieves break into the warehouse, they won’t be able to destroy the footage by simply breaking into
the security/AV room.

Reinforce Entryways. It is easy to focus so much on buying solid steel doors and fancy, high-priced
locks, but forget to ensure that the doorframe is just as robust for standard swing-style doors.
Reinforcing doorframes, using strong deadbolts, and installing long, high-durability door screws can
be just as important as having a tough door. Sources such as ACME Locksmith recommend changing
out 1/2 inch door screws for 3 1/2 inch versions since this makes it much harder to kick in a door. For
rolling doors, using high-strength locking mechanisms and thicker-gauge steel can prevent most
intrusion attempts. Windows should be reinforced and kept locked whenever the warehouse is not in
use. Rolling steel shutters can help further secure windows (and prove useful during hurricane
season).

Make Security Checks a Part of Closing Procedures. If your warehouse/distribution center isn’t
operating 24/7, it’s important to have a set process for shutting the facility down at the end of the
work day. Supervisors and/or security should check any security cages and locks to verify that they are
secure, patrol the facility to check for open windows/skylights/doors, and ensure that the facility is
empty before setting the alarm and leaving.

Run Background Checks on All Warehouse Staff. Internal theft is a major source of inventory
shrinkage for any business. Before entrusting someone with all of your most valuable products, it’s
necessary to verify their trustworthiness. Background checks on employees are a vital part of the
process for vetting new hires—especially if they’re going to be handling small, high-value items
frequently. Many businesses use background checks to vet their employees to help manage their risks.

Outsource Distribution and Fulfillment to a Proven Partner. Instead of trying to tackle warehouse
security (and spending money on warehouse floor space) on your own, you may want to consider
outsourcing to a third-party logistics partner. A 3PL solution helps you meet your order fulfillment
needs without you having to worry about specific fulfillment processes, finding the right security
solution, and other warehouse management concerns. Instead, you can save time and focus more on
developing your business.

warehouse maintenance

Warehouse maintenance refers to the system a business owner has in place to keep the facility storing
all of the company's products in functioning condition at all times. That means keeping conveyor
systems running, making sure cranes work, and repairing any machinery in a timely manner to prevent
disruptions to the day-to-day operations of a warehouse.

Types of warehouse maintenance

1. Scheduled or preventive maintenance

Scheduled maintenance refers to planned activities to keep equipment running and avoid sudden
breakdowns. For example, a piece of equipment may be scheduled for a certain type of maintenance
after 10,000 hours of use based on what historic usage indicates is the ideal time to perform it. This
lengthens the life of the equipment and makes breakdowns less likely.

2. Training
Workers are the key to effective maintenance. By training your workers to understand the equipment,
know how to maintain it, and identify potential problems before they happen, you improve your
overall maintenance practices and reduce the likelihood of a crippling breakdown.

3. Inspections

Inspections are key to maintenance because no matter how good your team is, sometimes they will
miss some less-obvious problems. By doing a thorough inspection at regular intervals, you can spot
emerging issues and recommend emergency maintenance to take care of them before the warehouse
is disrupted.

Best practices to improve warehouse maintenance

Warehouse maintenance requires a proactive approach and constant vigilance. Here are seven best
practices to help you increase your chances of avoiding a disruption.

1. Create a thorough maintenance manual

The most important aspect of warehouse maintenance is planning. You must devote significant time
and effort to a warehouse maintenance plan and a manual for your crew that they must adhere to.

The manual should describe in detail what the daily maintenance practices should be for each worker,
any special or scheduled maintenance, what inspections should be done and when, and how certain
maintenance issues should be dealt with. By making the manual thorough and easy to access, you
make it easier for your crew to do the work necessary to keep the facility running properly.

2. Set up a training program

The manual is the foundation for your maintenance effort, but it is not enough by itself. Create a
training program for all of your workers to make sure they fully understand their warehouse
maintenance duties. Set aside enough time to thoroughly train your employees, even if it costs you
money in lost production for a brief period. You will more than make up for it in more effective
maintenance.

3. Recruit certified workers

Warehouse managers should recruit the right people -- not just take anyone who's cheap and hope
that they can pick up the program. For example, forklift operators should be properly licensed and
certified -- not just because they understand how to do proper maintenance, but because it may be
required by laws and regulations.

4. Take safety precautions

Check that your crew has access to safety equipment such as helmets, harnesses, and anything else
that is required by the Occupational Safety and Health Administration -- or just based on your common
sense about the safety hazards they are likely to encounter. Equipment maintenance is often
dangerous, so it is a warehouse manager’s duty to protect the workers from safety hazards on the job
site.

5. Deal with pests aggressively

Pests are often an afterthought, but they can cause a serious disruption to your facility. They may
contaminate food or even damage equipment. Don't wait until a small pest problem becomes a big
one.
Take aggressive steps to do a warehouse cleaning and eliminate pests as soon as you see signs of
them. Call in a professional to conduct a thorough examination of your facility to see what the scope
of the problem is. Often an occasional rat is indicative of a serious problem you can't see deep inside
your warehouse.

6. Talk to your crew

Your crew are your eyes and ears on the warehouse floor. You don't work with the equipment in the
warehouse for hours each day, but they do.

Have regular conversations with them to understand what issues they're encountering such as
frequent breakdowns or a maintenance manual that is difficult to follow. They will help you spot small
problems before they become big ones, giving you an opportunity to address them proactively.

7. Use data

Thanks to today's software, it's never been easier to gather data about your operations, no matter
what industry you're in. Warehouse managers should gather information about equipment usage,
inventory turnover ratio, breakdowns, safety incidents, and anything else that is essential for your
business to track.

Take deep dives into these data to spot trends and opportunities for improvement. For example, the
information may show that your conveyor belts break down 20% faster than they should based on
industry standards, indicating that current maintenance practices should be adjusted. This is an insight
you might not have if you didn't look at the data.

Common warehouse maintenance challenges

There are some things that can get in your way when you try to establish preventive maintenance
procedures at your warehouse. Let’s briefly touch on those so you have an idea of what to expect and
avoid.

Poor warehouse layout design and organization

Poorly designed and organized warehouses can quickly become clutter zones. Performing
maintenance in such an environment will, at best, slow down the maintenance and repair process,
and at worst, cause safety concerns and serious operational delays.

Finding the right time for maintenance

Warehouses are swarming with workers and buzzing with activity 24/7, especially at distribution
centers. It can be difficult to carry out maintenance work if the place cannot shut down even for a few
hours. Scheduling the right date and time for proper maintenance requires you to plan ahead. One
way to solve this problem is by dividing the warehouse into different blocks. Each block is “under
maintenance” on a different day, hopefully when it’s set to experience the least amount of traffic.

Short window of time for repairs

Different types of warehouses have different purposes and different tolerance for delays. If a public
warehouse that works at half capacity experiences an unexpected equipment failure that causes a
two-hour operational delay, it is not the end of the world. In contrast, if the same happens at a semi-
automated Amazon warehouse, hundreds of e-commerce customers might be left frustrated by the
lack of same-day delivery service they paid for.
Warehouse Stock Location Systems

Location systems are one of the core components of a successful warehouse operation. Their base
function is providing easy, logical access to a physical location in the warehouse.

When an operator sees a location on the wireless device or paper ticket, it should immediately be
clear which is the most efficient path to the desired location.

Standard nomenclature has been created for designing locations. An example might be: D-13-37-5-
2.

Where:

D: Building, room, or area of warehouse: If you have a box for a warehouse, you may not
need this field. This field separates physical areas of the warehouse or site. There may be
separate temperature control rooms, separate buildings, or secure rooms. This code enables
the operator to determine the correct area of the operation quickly.

13: Aisle: This field identifies the aisle number.

37: Bay: This field marks the bay number in the aisle, typically the locations in a rack bay. In
a bulk or floor location, this is the number of the location in the row.

5: Level: This field indicates the level off the floor.

2: Position: This is the horizontal position on a rack or shelf. For instance, a shelf may be
divided into four locations. The locations would be numbered 1 to 4.

This format would vary according to the type of location. Bulk or floor locations might only have area,
aisle, and bay, D-13-37. An offsite warehouse may only have an area or area and aisle. The warehouse
would determine the best mix designed around their operation.

Basic Principles

There are some basic principles involved in designing an effective and efficient stock location system:

⦁ Keep It Simple

⦁ Provide Security

⦁ Make it Permanent

⦁ Make it Flexible

⦁ Make it Expandable

Application of computing in warehousing management

Manual warehouse

Manual warehouses / storage systems are storage locations and racking systems which are not
accessed by automated systems, but operated by humans. Such warehouses can be narrow aisle
warehouses, manual pallet racks or shelf storage systems.

In most cases, access to the storage locations is ensured through the "man-to-goods" principle.
Especially in narrow aisle warehouses, however, you can also find order picking stations where goods
are collected or made available (goods-to-man).
Manual warehouse and its special features

The general warehouse topology and the coordinate system do not differ from automatic warehouses.
With the latter, merely the automation in terms of the operating device is fixed.

Transport control is identical as well. However, when the man-to-goods principle is applied, no route
optimization take place like in the case of an AS/RS, but routes can be saved that describe zig-zag,
loops, U-courses and any other sequence.

Manual warehouses can also be supported by conveyors ensuring material supply and disposal.
Accordingly, handover positions and zones/stations are configured and which storage areas and aisles
they operate. In most cases, processing takes place without vouchers (RF, voice) or with storage and
picking documents which then are reported back.

Several load handling attachments

The control system and the MFC (material flow computer) are able to use several load handling
attachments (and multiple load handling attachments) in an optimal manner. Corresponding
installations with pallet AS/RS are in use at Rotho and Marburger Tapeten.

Route optimization through several load handling attachments

In case of several load handling attachments accumulating runs are possible that allow a high
throughput even with slower devices. In X-direction, the AS/RS feature two load handling
attachments.

Order planning is done according to the route optimization by building packages (transport sequences)
to place an order with the AS/RS. During this process, both load handling attachments are considered.
If no second order exists at the time the order is allocated (only one load handling attachment
occupied), the transport orders are again read after taking up the first loading unit to account for
changes.

It is also taken into account that possibly not all storage locations or handover positions to the
conveyor system can be reached by both load handling attachments (due to the racking design). Their
sphere of action is defined by configuring the load handling attachments.

In case one load handling attachment fails (defective), the configuration also allows changing the
settings such that orders are assigned to the AS/RS correspondingly with only one load handling
attachment. Operating such devices is possible in automatic small parts warehouses and high-bay
warehouses.

Computerized or Automatic Warehousing Systems

A business automation platform helps with warehouse management in many ways.

Auto reorder points on parts, inventory tracking across multiple locations, and easy access to multiple
shippers are just a few of those ways.

Cycle counts can be performed with handheld devices to instantly update inventory quantities instead
of having workers write down notes with a pen and paper and later add those numbers into a desktop
computer.
Plus, you can organize your warehouse into three categories to put similar-sized and similar-selling
items close to each other for more efficient storage and picking.

Advantages:

• Decreases overall labor costs and constraints while simultaneously increasing safety of both
products and employees.
• Inventory quantities can be instantly updated in real-time to ensure accuracy of product
availability and location.
• Reduces order fulfillment inaccuracies due to human error.
• Achieves increased productivity and efficiency, as seen in the innovative Next Generation
Films automated warehouse.
• Allows for a reduction of storage space footprints while also optimizing the utilization of
vertical ceiling clearances.

Disadvantages:

Requires a high initial investment.

Is mostly suitable for repetitive and predictable operations.

Employees must have technical skills and undergo trainings to correctly and safely operate new
equipment and software.

Warehousing Equipment and Machinery

Why is Equipment and machinery Important?

Efficient Material Handling: The material handling equipment helps you store, move, load, and ship
out your material. The choice of equipment speeds up this process and adds to the staff’s convenience.
From unloading trucks, storing to shipping out, you must follow material handling protocol. And the
MHE helps you facilitate all these operations efficiently within the warehouse.

Reducing the Cost of Warehouse Operations: If you choose the wrong MHE or work with insufficient
MHE, you are likely to lose efficiency. The right MHE accelerates the process of controlling the material
and orders. And this efficiency translates into reduced operations and shipping costs.

Preventing Workplace Accidents and Material Damage: You cannot run a warehouse efficiently with
makeshift arrangements. Material handling has a high risk of material damage based on the type of
material. Moreover, makeshift arrangements mark a crucial risk of fatal accidents. And it violates the
labor safety protocol. With that said, you need a material handling equipment setup to eliminate these
risks. You might also need extra safety equipment like safety bollards, door track guards, etc.

Enhancing the Accuracy of Supply Chain Management: MHE helps you support the automation for
your warehouse management. Be it deciding the LIFO or FIFO strategies, finding or shipping out
orders, MHE delivers accuracy. And therefore, there is less to no back & forth. The material handling
equipment increases the overall supply chain efficiency and accuracy.

TYPES OF WAREHOUSE EQUIPMENT AND MACHINERY

The equipment and machinery used in warehouses make for a lengthy list but can be roughly clustered
into several groups: storage equipment, transfer & handling equipment, picking/packing/palletizing
equipment, and equipment used in managing warehouse operations. Warehouses run the gamut from
those that house mostly identical items to those that store many thousands of unique products from
which each shipment has to be individually picked. This article briefly looks at some of the more
common items on this list that could be found in a typical warehouse.

Storage

Warehouse storage is usually of either the bulk or rack variety, where bulk storage pallets are typically
just stored on a floor and where rack storage pallets are stacked on racks to make use of higher ceiling
space. Typical rack warehouse storage equipment includes pallet racks and wire decking, heavy-duty
shelving, cantilevered racks, reel racks, and, sometimes, high-density storage systems such as drive-in
racking, push back racking, and pallet flow racking. High-density systems are sometimes able to
increase the usage of existing space enough that the need for building additional storage facilities can
be avoided. Inventory systems such as FIFO (first in, first out) have some bearing on which of these
high-density systems are suitable. Aisle space is referred to as narrow aisle (NA) or very narrow aisle
(VNA) and can place a limit on lift maneuverability. A typical counterbalanced lift truck needs at least
11 ft. of aisle width to turn around. Three-wheel pallet jacks are often employed in warehouses due
to their improved ability to navigate through tight corridors.

Transfer and Handling

Moving material around a warehouse involves lifts and trucks of many kinds, such as pallet jacks, lift
trucks, hand trucks, scissor lifts, stackers, etc. Special designs such as narrow-aisle forklifts are
available for high-density storage schemes. Wire- or rail-guided reach trucks are sometimes employed
in narrow-aisle warehouses to maximize the use of storage space. Such automation, known as
automated storage and retrieval, can reduce personnel requirements – at a cost. Often, such systems
use horizontal or vertical carousels for the storage of stock. Special attachments are available for
forklifts for handling unpalletized loads such as paper rolls or storage drums.

Conveyor systems of various kinds are also employed in some warehouses for the movement of picked
goods. Both gravity and live roller conveyors are common as are skatewheel conveyors. Temporary,
flexible conveyors are sometimes used as well. See related guides Understanding Conveyor Systems
and Types of Trucks and Carts for additional information on transfer and handling equipment.

Picking/Packing/Palletizing

Picking operations can be done order-by-order, called discrete picking, or simultaneously on multiple
orders, also called batch picking. Zone picking is another method, where multiple pickers work on the
same order for later assembly. When whole pallets are pulled from racks it is called pallet, or unit load,
picking. Case picking refers to removing cases of like products. Piece picking, or broken-case picking,
describes the picking of individual items as might apply to a mail-order catalog operation or a repair
parts distributor.

Order picker forklifts are designed to elevate both pallet and operator to the level of racked goods, a
so-called man up operation. For bulk storage warehouses, case picking usually involves a manual or
electric pallet jack that the picker moves from location to location as the cases making up the order
are selected. Palletized orders may be stacked using pallet positioners for better worker ergonomics.
Palletized loads are stabilized with bands or shrink-wrap applied manually or by machine. Loads are
then trucked to loading docks and into trailer containers. Here, a variety of equipment is in service,
including trailer leveling jacks and chocks, dock plates, dock seals, and air curtains. Automated
restraint systems reduce the chance of a truck pulling away from the dock as it is still being loaded.
Elevating docks are used where raised docks are unavailable. Signals provide communication to truck
drivers and lift operators.
Operations

Warehouse management such as keeping tabs on materials and goods moving to, from, and through
a warehouse is often aided by the use of mobile workstations and handheld devices. With such
equipment available to them, warehouse workers are able to move throughout the warehouse and
have necessary data such as pick lists immediately at hand. Barcoding and RFID tags are used to further
streamline the process. Warehouse management software is used to track the flow of goods through
a facility, including receiving, putaway, picking, shipping, and inventorying. Such software is
sometimes used to initiate slotting, the arranging of stock within a warehouse to improve picking
efficiency. Regardless of the picking method or the nature of the picking (piece, case, pallet), a rule of
thumb says that the items moved most frequently should be stored closest to the pick point to
minimize transit times, which make up a large portion of most picking cycles.

In-plant offices and mezzanines can be set up for office personnel and for additional use of warehouse
space. Lockable storage in the form of security cages is also available.

Worker safety is a primary concern in a busy warehouse. Racks are often buttressed at their ends to
protect them from forklift collisions. Racks are usually fenced or enclosed along one side to avoid
boxes from being pushed through and falling during handling. Many lifts are equipped with overhead
guards to protect operators against injury from falling stock. Pickers wear appropriate harnesses to
protect them from falls.

Some warehouse operations skip the putaway step and goods move from receiving directly to
shipping. This process is called cross-docking and it is employed mainly in warehouses and distribution
centers involved in the retail trades.
MAKE UP CLASS DISCUSSION

Room 1(4)
Already in room
Don. Conrad Mogaka, Loureen Ogake Gekonge, SAMUEL KARANJA, stephen ongeri
[11:25] LectureTo join this meeting by phone, dial: 0111017734Then enter 742 981 as the conference
PIN number. To mute or unmute,dial 0.Welcome/Karibu.
[11:26] Don. Conrad Mogaka: Need for warehousing
[11:26] stephen ongeri: ok sir
[11:27] stephen ongeri: stephen ongeri BUS-245-106/2021
[11:27] Victor kiheko: Victor kiheko BUS-245-044/2021
[11:28] SAMUEL KARANJA: We are not sending admission no. We are discussing 🤷amka bwana
[11:29] SAMUEL KARANJA: SAMUEL KARANJA BUS-245-009/2021
[11:33] Victor kiheko: Hatuezi kuongea
[11:33] Victor kiheko: But tunaona staff unafanya
[11:34] Victor kiheko: Yeah
[11:37] SAMUEL KARANJA: Unaongea si unaona microphone apo ivo
[11:37] Victor kiheko: Mm niko kwa listen only
Room 2(5)
Already in room
Don. Conrad Mogaka, Elizabeth Kanyotu, Nina Omwoma, Rose mbuthia, Wandurwa Catherine
Nyambura
[11:26] LectureTo join this meeting by phone, dial: 0111017734Then enter 742 982 as the conference
PIN number. To mute or unmute,dial 0.Welcome/Karibu.
[11:27] Don. Conrad Mogaka: Types of warehouses
[11:28] Rose mbuthia: Yangu inakataa kutumia microphone
[11:28] Elizabeth Kanyotu: Elizabeth Wanjiku
[11:28] Nina Omwoma: Nina omwoma- BUS-245-057/2021
[11:28] Elizabeth Kanyotu: BUS-245-111/2021
[11:29] Rose mbuthia: Mbuthia Rose BUS-245-002/2020
[11:33] Rose mbuthia: Si we discuss aki, lec has said that we have 7 types of warehouses
[11:33] Wandurwa Catherine Nyambura: Inakataa kutumia microphone
[11:34] Rose mbuthia: 3 main types are Public warehouse, private and bonded
[11:34] Wandurwa Catherine Nyambura: Public warehouse

This is owned by people who give space to the public

[11:34] Wandurwa Catherine Nyambura: Private
[11:35] Rose mbuthia: The rest are field warehouse, raw material warehouse, finished goods warehouse
and distribution
[11:36] Nina Omwoma: Bonded warehouses are also known as customs warehouses is a building where
imported goods are stored and can be manipulated
[11:36] Wandurwa Catherine Nyambura: Then kuna raw materials warehouse for storing materials used
in production and manufacturing process
[11:36] Rose mbuthia: Bonded warehouses are owned and managed by the government
[11:37] Rose mbuthia: Na lec aambiwe anaongea haraka sana sometimes hatushiki points
[11:37] Wandurwa Catherine Nyambura: Private warehouse are owned by individuals who use them for
their own purposes and do mot lender space to other people
[11:37] Wandurwa Catherine Nyambura: Kanyotu
[11:38] Nina Omwoma: I’ve found one called climate controlled warehouses where It's a storage area
where the temperature and humidity are or can be carefully controlled, or set to remain within certain
parameters so that these factors are consistent all the time.
[11:39] Nina Omwoma: Tumepata nne what are the other 3?
[11:39] Wandurwa Catherine Nyambura: Field warehouse
[11:40] Rose mbuthia: Nina we said apart from the three main, lec added field warehouse, rawmaterial
warehouse and finished goods warehouse and distribution warehouse
Room 3(6)
Already in room
Don. Conrad Mogaka, Kelvin Musyoki, MUTUNGA LINDA NZILANI, Patrick Kamunu Ngugi, Stephene
Wanyama, Victor Gicheha
[11:27] LectureTo join this meeting by phone, dial: 0111017734Then enter 742 983 as the conference
PIN number. To mute or unmute,dial 0.Welcome/Karibu.
[11:28] Don. Conrad Mogaka: Warehouse design & layout principles
[11:38] Victor Gicheha: Victor Gicheha BUS-245-017/2021
[11:38] Kelvin Musyoki: Musyoki Kelvin BUS-245-037/2021
[11:39] Patrick Kamunu Ngugi: Patrick Kamunu BUS-245-026/2021
[11:39] MUTUNGA LINDA NZILANI: Linda Nzilani BUS-245-031/2021
Room 4(4)
Already in room
Don. Conrad Mogaka, Lorraine Cherotich Langat, Mercy Munene, Oscar Otieno
[11:29] LectureTo join this meeting by phone, dial: 0111017734Then enter 742 984 as the conference
PIN number. To mute or unmute,dial 0.Welcome/Karibu.
[11:29] Don. Conrad Mogaka: Three layout designs
[11:29] Collins Kiplagat: Okay sir
[11:30] Collins Kiplagat: BUS-245-050/2021
[11:33] Collins Kiplagat: The three layout designs are
[11:34] Collins Kiplagat: The I-shaped U-shaped and the L-shaped
Room 5(5)
Already in room
Don. Conrad Mogaka, GITUKU HOPE GRACE NJERI, Glen Jacks Odindo, NGWATE JULIUS MUNYOKI,
Teddy Sakwa
[11:30] Lecture To join this meeting by phone, dial: 0111017734Then enter 742 985 as the conference
PIN number. To mute or unmute,dial 0.Welcome/Karibu.

[11:31] Don. Conrad Mogaka: Value addition, returns management and put away

[11:31] Don. Conrad Mogaka: Type name and admission number here

[11:32] Teddy Sakwa: Teddy Sakwa Bus-245-108/2021

[11:33] NGWATE JULIUS MUNYOKI: Julius Munyoki Ngwate Bus-245-034/2021

[11:33] Glen Jacks Odindo: Glen Jacks Odindo Bus-245-112/2021

[11:34] GITUKU HOPE GRACE NJERI: Maureen is experiencing some network connection and has been
left from the meeting kindly resend the link for her

[11:35] GITUKU HOPE GRACE NJERI: Hope Njeri

[11:35] GITUKU HOPE GRACE NJERI: Hope Njeri BUS-245-020/2021

[11:37] Don. Conrad Mogaka: She's been invited

[11:38] Maureen Mwongeli: Maureen Mwongeli BUS-245-033/2021

FINAL CLASS ATTENDANCE

[11:51] LectureTo join this meeting by phone, dial: 0111017734Then enter 74298 as the conference
PIN number. To mute or unmute,dial 0.Welcome/Karibu.

[11:56] The public chat history was cleared by a moderator

[12:08] Kelvin Musyoki: Musyoki Kelvin BUS-245-037/2021

[12:08] Maureen Mwongeli: Maureen Mwongeli BUS-245-033/2021

[12:08] stephen ongeri: stephen ongeri BUS-245-106/2021

[12:08] Victor Gicheha: Victor Gicheha - BUS-245-017/2021

[12:09] NGWATE JULIUS MUNYOKI: JULIUS MUNYOKI NGWATE Bus-245-034/2021

[12:09] Rose mbuthia: Mbuthia Rose Muthoni BUS-245-002/2020

[12:09] Teddy Sakwa: Teddy Sakwa Bus-245-108/2021

[12:09] Victor Kiheko: Victor kiheko BUS-245-044/2021

[12:09] Patrick Kamunu Ngugi: PatrickKamunu BUS-245-026/2021

[12:09] MUTUNGA LINDA NZILANI: Linda Nzilani Mutunga BUS-245-031/2021

[12:09] Nina Omwoma: Nina Omwoma BUS-245-057/2021

[12:09] RUWA FAUZIA MUPA: RUWA FAUZIA MUPA BUS-245-042/2021

[12:09] Stephene Wanyama: Stephene Wanyama BUS-245-053/2021

[12:10] Elizabeth Kanyotu: Elizabeth Kanyotu BUS-245-111/2021

[12:10] GITUKU HOPE GRACE NJERI: Hope Njeri BUS-245-020/2021

[12:10] Lorraine Cherotich Langat: Lorraine Cherotich Langat.Bus-245-048/2021