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Warehouse Process and its layout

Sourabh Gupta

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What you'll learn

The course objectives of warehouse process for engineering students are designed to provide a comprehensive understanding of warehouse management, logistics, and material handling, and to prepare students for careers in the field of industrial engineering and logistics.

Key topics covered

  • Introduction Warehousing
  • Warehousing Process
  • Inbound Process (IB)
  • Inventory Process
  • Outbound Process (OB)
  • Return Center
  • Warehouse Layout 
  • Process flow of IB
  • Process flow of OB


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Course Details

Warehouse process is a field of study that deals with the management of warehouse operations, material handling, and logistics. It is an important topic for engineering students, particularly those interested in industrial engineering or logistics.

The course objectives of warehouse process for engineering students may include:

  1. Understanding the basic principles of warehouse management and logistics.
  2. Developing knowledge of material handling techniques, including storage and retrieval systems, conveyor systems, and automated storage and retrieval systems (AS/RS).
  3. Familiarizing with the latest technologies and software used in warehouse management, such as Warehouse Management Systems (WMS) and Enterprise Resource Planning (ERP).
  4. Developing an understanding of inventory management, including forecasting, demand planning, and safety stock.
  5. Developing an understanding of Lean principles and how they can be applied to warehouse operations to improve efficiency and reduce waste.
  6. Learning about the safety regulations and best practices in warehouse management to prevent workplace accidents and injuries.
  7. Developing skills in analyzing warehouse operations, identifying bottlenecks, and proposing solutions to improve efficiency.
  8. Understanding the role of the warehouse in the broader supply chain and how to optimize warehouse operations to improve overall supply chain performance.

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Course tags

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Industry domains :

Oil & Gas

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Engineering Disciplines :

Mechanical , Electrical , Process

Course content

1

Introduction of warehouse :

A warehouse is a building or facility used for the storage and handling of goods and materials. Warehouses are designed to provide a safe and secure environment for goods to be stored, and they are an important component of supply chain management. Warehouses come in many different shapes and sizes and can range from small storage facilities to large distribution centers. They are typically designed to accommodate the specific needs of the goods being stored, with features such as loading docks, high ceilings, and temperature control systems. In addition to storage, warehouses also typically provide other services such as inventory management, order fulfillment, and shipping and receiving. Many warehouses are also equipped with material handling equipment such as forklifts, conveyor systems, and pallet jacks to facilitate the movement of goods within the facility.

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2

Introduction of warehouse :

A warehouse is a building or facility used for the storage and handling of goods and materials. Warehouses are designed to provide a safe and secure environment for goods to be stored, and they are an important component of supply chain management. Warehouses come in many different shapes and sizes and can range from small storage facilities to large distribution centers. They are typically designed to accommodate the specific needs of the goods being stored, with features such as loading docks, high ceilings, and temperature control systems. In addition to storage, warehouses also typically provide other services such as inventory management, order fulfillment, and shipping and receiving. Many warehouses are also equipped with material handling equipment such as forklifts, conveyor systems, and pallet jacks to facilitate the movement of goods within the facility.

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3

Inventory process :

The inventory process typically includes the following steps: Stocking: Goods are received from suppliers and placed in their assigned storage locations within the warehouse. The inventory management system is updated to reflect the new inventory levels. Monitoring: The inventory levels of each product are continuously monitored to ensure that they remain within their target ranges. This may involve regular physical inventory counts or the use of automated inventory tracking systems. Replenishment: When inventory levels fall below their target ranges, the inventory management system generates a replenishment order. This order is sent to the supplier to ensure that new inventory is delivered in a timely manner. Order fulfillment: As orders are received from customers, the inventory management system checks the inventory levels to ensure that the requested products are in stock. If the products are available, they are retrieved from the warehouse and prepared for shipment. If the products are not available, the inventory management system may generate a backorder or suggest an alternative product. Returns processing: If products are returned by customers, the inventory management system ensures that they are properly identified, processed, and restocked in the warehouse. Reporting and analysis: The inventory management system provides regular reports and analysis on inventory levels, inventory turns, and other inventory-related metrics. This information is used to optimize inventory levels and improve overall supply chain performance. Overall, the inventory process is a critical component of warehouse management, as it ensures that the right goods are available at the right time to meet customer demand, while minimizing the costs associated with carrying excess inventory. By optimizing the inventory process, warehouses can improve customer satisfaction, reduce costs, and improve overall supply chain performance.

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4

Return center :

A return center process is an essential component of warehouse management that deals with the processing of customer returns. A return center process involves several steps that ensure customer satisfaction while minimizing costs associated with handling returns. The following are the steps involved in the return center process: Receiving the Return: When a customer wants to return a product, they contact the retailer or warehouse and request a return. The warehouse staff will receive the returned product, and it is checked for damage, missing parts, or signs of wear and tear. Sortation and Disposition: The warehouse staff will sort the returned products based on their condition. If the product is in good condition, it may be restocked for resale. If it is damaged, the warehouse staff may evaluate whether it can be repaired, recycled or if it needs to be discarded. Restocking: If the product is in good condition, it is restocked for resale. The warehouse staff will update the inventory system to reflect the returned product’s availability, and it is placed back into the inventory for sale. Refurbishing: If the product is in good condition but requires refurbishing, the warehouse staff will perform necessary repairs, cleaning, or reconditioning. Recycling: If the product is not fit for resale, it may be recycled. The warehouse staff will identify the components that can be salvaged and recycled. Record Keeping: The warehouse staff will maintain records of all returned products, including the reason for return, condition, and final disposition. This information is used to analyze return patterns, identify product quality issues, and inform future decisions about inventory management. Overall, the return center process is an essential part of warehouse management that ensures customer satisfaction while minimizing costs associated with handling returns. By optimizing the return center process, warehouses can improve customer satisfaction, reduce costs, and improve overall supply chain performance.

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Process flow of inbound :

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6

Return center :

A return center process is an essential component of warehouse management that deals with the processing of customer returns. A return center process involves several steps that ensure customer satisfaction while minimizing costs associated with handling returns. The following are the steps involved in the return center process: Receiving the Return: When a customer wants to return a product, they contact the retailer or warehouse and request a return. The warehouse staff will receive the returned product, and it is checked for damage, missing parts, or signs of wear and tear. Sortation and Disposition: The warehouse staff will sort the returned products based on their condition. If the product is in good condition, it may be restocked for resale. If it is damaged, the warehouse staff may evaluate whether it can be repaired, recycled or if it needs to be discarded. Restocking: If the product is in good condition, it is restocked for resale. The warehouse staff will update the inventory system to reflect the returned product’s availability, and it is placed back into the inventory for sale. Refurbishing: If the product is in good condition but requires refurbishing, the warehouse staff will perform necessary repairs, cleaning, or reconditioning. Recycling: If the product is not fit for resale, it may be recycled. The warehouse staff will identify the components that can be salvaged and recycled. Record Keeping: The warehouse staff will maintain records of all returned products, including the reason for return, condition, and final disposition. This information is used to analyze return patterns, identify product quality issues, and inform future decisions about inventory management. Overall, the return center process is an essential part of warehouse management that ensures customer satisfaction while minimizing costs associated with handling returns. By optimizing the return center process, warehouses can improve customer satisfaction, reduce costs, and improve overall supply chain performance.

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7

Warehouse layout structure :

the structure of a warehouse plant is crucial in maximizing space utilization, improving inventory management, and optimizing operational efficiency. By designing a well-structured warehouse plant, businesses can improve productivity, reduce costs, and enhance customer satisfaction.

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8

Process flow of inbound :

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Process flow of outbound :

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10

Inbound process :

Inbound process, also known as inbound logistics, refers to the activities involved in receiving, handling, and storing raw materials, parts, and other goods as they enter a warehouse or distribution center. The goal of the inbound process is to ensure that incoming goods are received, processed, and stored efficiently and accurately, so that they can be quickly and easily located when needed for production or distribution. The inbound process typically includes the following steps: Receiving: Goods are received at the warehouse or distribution center, and the receiving team inspects them to ensure that they meet the order specifications and quality standards. The goods are then assigned a location within the warehouse and recorded in the inventory management system. Unloading: Goods are unloaded from the delivery vehicles and transported to the designated storage area within the warehouse. This process may involve the use of material handling equipment such as forklifts or conveyor systems. Checking: The goods are checked against the purchase order and other documentation to ensure that they are accurate and complete. Sorting and Labeling: Goods are sorted according to their type and assigned a unique location within the warehouse. They are also labeled with barcodes or other identification codes for easy tracking and retrieval. Putaway: Goods are placed in their assigned storage location within the warehouse using standard procedures and equipment. Updating Inventory: The inventory management system is updated with the new inventory information, including the location, quantity, and other details of the incoming goods. Overall, the inbound process is a critical component of warehouse management, as it ensures that goods are received, processed, and stored efficiently and accurately. By optimizing the inbound process, warehouses can improve inventory accuracy, reduce lead times, and improve overall supply chain performance.

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11

Outbound process :

Outbound process, also known as outbound logistics, refers to the activities involved in the handling, processing, and shipping of goods and materials from a warehouse or distribution center to the end customer. The goal of the outbound process is to ensure that products are delivered to customers quickly, accurately, and at the lowest possible cost. The outbound process typically includes the following steps: Order Processing: Orders are received from customers, and the inventory management system checks the inventory levels to ensure that the requested products are available in the warehouse. Order Picking: Once the order has been confirmed, the warehouse staff picks the products from their assigned storage locations within the warehouse. Order Packing: The picked products are then packed into boxes or other containers for shipment to the customer. The packing process may involve adding packing materials such as bubble wrap or packing peanuts to protect the products during shipping. Shipping: The packed products are loaded onto trucks or other shipping vehicles and transported to the customer. The shipping process may involve working with third-party logistics providers or shipping companies to ensure that the products are delivered on time and at the lowest possible cost. Order Tracking: The inventory management system provides real-time tracking information to the customer so that they can track the progress of their shipment. Returns Processing: If customers need to return products, the warehouse staff ensures that the products are properly identified, processed, and restocked in the warehouse. Overall, the outbound process is a critical component of warehouse management, as it ensures that products are delivered to customers quickly, accurately, and at the lowest possible cost. By optimizing the outbound process, warehouses can improve customer satisfaction, reduce costs, and improve overall supply chain performance.

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12

Warehouse layout structure :

the structure of a warehouse plant is crucial in maximizing space utilization, improving inventory management, and optimizing operational efficiency. By designing a well-structured warehouse plant, businesses can improve productivity, reduce costs, and enhance customer satisfaction.

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13

Process flow of outbound :

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