Research Papers: As a kick start to the project we studied the following papers: 1.

A Comprehensive Model of Traditional Warehouse and $unter (harp This paper introduces the concept of workflow in warehouse design. The warehouse processes have "een classified into functions stating the re)uirements and design features of each. *t esta"lishes a foundation for warehouse design workflow "# presenting the concept of workflow and wh# a warehouse design workflow +W W, is desira"le& descri"ing the re)uirements for the W W& descri"ing the criteria "# which a proposed workflow can "e evaluated and finall# presenting in detail the modeling principles necessar# to support the framework for developing such workflows -. A (#stematic Warehouse esign Workflow: .ocus on Critical ecisions! "# $unter (harp& Marc esign! "# Marc $oetschalck%& 'eon Mc$innis

$oetschalck% and 'eon Mc$innis This paper illustrates the warehouse design workflow +W W, concept that was introduced in the a"ove companion paper with an e%ample. The design decisions have "een organi/ed ver# well to permit ma%imum use of the workflow model. A "rief reiteration of conceptual warehouse model is followed "# organi/ing the design decisions into specific set of pro"lems to provide a graphical description of the workflow. The paper ends with a description of opportunities for further research and possi"ilities of refining the workflow. These papers "esides defining the Warehouse esign Workflow +W W, in ever# detail aim at

making the workflow computational. The# do not talk a"out the tools that could possi"l# "e used to design warehouse functions and their capacities. The# have helped us in understanding the W W entirel# "# which we could come up with different wa#s to make this project computational. Appl#ing the W W concept to real warehouse cases ena"led us in figuring out the limitations of the tools with respect to the design re)uirements. 0efore we descri"e the application it is necessar# to summari/e the papers to give an idea to the reader.

1. A Comprehensive Model of Traditional Warehouse Design The warehouse design workflow concept is relativel# new. *t is called a workflow and not a procedure "ecause instead of providing details for each step we actuall# give feasi"le choices for ever# decision pro"lem. Warehouse flows can "e classified as fulfillment flows& to satisf# demand and in"ound flows from suppliers. The o"jective of a warehouse is to s#nchroni/e and handle these flows in an efficient and cost effective manner. 1ach flow can "e characteri/ed "# its fre)uenc# and amplitude +)uantit#,. 0atching in these flows is the motivation for designing capacities of warehouse processes. Warehouse functions have "een split into 2 categories: receiving and shipping& storage& fulfillment& order assem"l#& transportation which are associated with the flows. The ta"le "elow is a "rief summar# of the functions and its features: Requirement Function Shipping and Receiving s ock doors 1)uipment (pace 'a"or Drivers Amplitude of customer orders Design Factors .re)uenc# and amplitude of flows ock door turn over (taging capacit# (taging capacit# *nventor# management policies (ku attri"utes 4rder picking +fulfillment activities,

Storage

(torage Media

3ature of customer order

(ku attri"utes 3ature of storage and retrieval operations Material Fulfillment handling 'a"or 'ines and )uantit# per order Total sku5s& ph#sical sku attri"utes& 6uantit# and fre)uenc# of sku

(hould alwa#s interact with storage functi

Order assembly

1)uipment& (pace 'a"or (pace& 7icking method .low from fulfillment function Compati"le with fulfillment function

.low from all the a"ove functions Total flow to fill orders

Transport

1)uipment

A .unction .low 3etwork +..3, descri"es the fundamental architecture of warehouse design. *t consists of nodes and arcs. 3odes are the four functions and arcs correspond to transportation& flow of goods "etween functions. The first step of warehouse design is to specif# the function flow network which narrows our options in su"se)uent stages.

7roposed workflow: The proposed workflow is "ased on decomposition and iterative e%ecution. ecomposition "reaks

the design pro"lem into a num"er of su"8pro"lems. 1ach of these su"8pro"lems is se)uentiall# designed and mutuall# consistent in that the higher level decision imposes constraints on the lower level decisions. The design is e%ecuted in si% distinct steps as shown

The level to data to "e considered for design at each step is limited "# the decisions made in the earlier steps. The design is iterative in that& if the outcome at the end of an# step is found to "e infeasi"le with respect to our re)uirements then it should "e possi"le to "acktrack to an# previous step to change decisions and then follow the workflow from there on. At the end of all steps the design is completed. etailed anal#sis at each step will estimate the capa"ilit# of the design

The following ta"le considers each design su"8pro"lem in its entire comple%it# and determines the re)uirements to generate an effective design for the pro"lem under consideration. Most of the resulting design specifications are carried through the workflow to impose design constraints on other su"8pro"lems and make them mutuall# consistent.

Input Profiling information replenishment orders inventor# retrieval orders Profiling information Functional areas existence storage modes product assignments

Design Sub-problem

Function Flo

!et or" Design

Output Functional areas existence storage modes product assignments

Functional area si es product inventor# )uantities Functional Area #i$ing

Shipping and receiving doc! Profiling information no. of docks Receiving and #hipping Doc" "arrier information in"ound carriers out"ound carriers Shipping and receiving doc! si es no. of docks no. and si/e of pick waves assignment and schedule #$uipment% &abor-cost% capacity Retrieval Order Information 3o. of orders volume per order order pick method #$uipment% &abor-cost% capacity Sorting and Pac!ing area area si/es operating policies Pic!ing System Pic"ing #%stems Design 9oning 0atching picking policies Design no. and si/e of pick waves assignment and schedule si es

#orting and Pac"ing Design

The la#out has not "een descri"ed and there is no literature availa"le on warehouse la#out. A la#out must contain each of the functions. .lows "etween functions& and function si/es have to "e considered in defining la#out.

The paper has provided with an ad hoc workflow which is "ased on reasona"le su"8 pro"lems and conve#s that its functionalit# would "e completel# e%posed when implemented in a computational form.

&. A #%stematic Warehouse Design Wor"flo : Focus on Critical Decisions

As we have discussed the design starts from specif#ing the ..3. To determine what functions are performed at what locations the designer must know the flow origin& flow destination and handling units. :ave known all this the designer can then determine the transformation processes that must occur to sustain the flow. .or e%ample& if homogeneous pallets enter and non homogeneous cartons leave& order picking must occur. The decisions during the design process are made with respect to flows& functions and transformations while the resulting design is e%pressed in terms of locations& resources and performance measures. 1ach of these elements has "een organi/ed "# t#pe& using the flowing coding: C8constraints& 8data& 78parameters& ;8decisions& M8measure of performance A num"er of e%amples are provided for each of the t#pes.

Warehouse design decisions are to "e organi/ed "efore proceeding with the workflow. .irst step is to o"tain information on product& order and operational data. 7roduct data includes information on product dimensions& value& handling units& seasonalit# etc. 4rder data is the e%pected customer orders: num"er of products& ship method& handling units shipped and seasonalit#. 4perational data is the operating policies of the warehouse like hours of operation& warehouse management s#stem used& la"or availa"le& num"er of shifts& e)uipment used& facilit# limitations etc. The workflow is structured as 2 levels. The higher level decisions form constraints for lower level decisions. The evaluation of a lower level decision indicates a need to go to "ack to higher level+s, and change the decision+s,. 1ach of the design su"8pro"lems is discussed in detail. The design pro"lem is carried out in levels with each level specif#ing the su"8pro"lem decision in detail Level 1 - Specify FFN *n the first iteration decide functional departments and process flows for each product t#pe. *n the first iteration without product profiling it ma# not "e possi"le to completel# specif# ..3. :ence it can "e com"ined with product profiling 0est wa# to start off is to have onl# one storage department for each handling while the# could "e split in later iterations

Level 2 Pro uct an

!r er Profiling" #ime $in o%s" Doc&s

7roduct profiling is grouping products into classes "ased on their storage re)uirements& handling units& process plans& pick fre)uenc# and flow volume. *n first iteration let products "e grouped onl# "# handling units. Modif# this in the ne%t iterations it re)uired to reflect product activit#. .or dock anal#sis in"ound receipt and out"ound shipment data like fre)uenc#& timing& order si/e is used to compute loading and unloading time which gives an estimate of dock doors needed. This does not change with iterations. ecide time such that an# operation that "egins in a time window must end in the same window. Time windows are specified "# their length. 4perations could cross a time window onl# if "uffers are in place. 4ne time window is recommended in iteration one. 4rder profiling can "e done with respect to customer& order )uantit#& sku attri"utes to give the no. of orders. *t can "e used to estimate the staging and docking areas and also cross check preceding

dock anal#sis. *n first iteration it is recommended to profile orders on the "asis of ship method or handling unit transformation +pallet < carton& carton < item& carton < carton,. Level ' (ones" Pro uct )ssignment to Storage (ones A /one can "e defined as a set of storage locations to which workers are assigned and has access to all storage locations in that /one. A principle is that onl# one t#pe of storage medium is assigned to a /one. (o the num"er of /ones is definitel# not less than the num"er of storage media t#pes. .or the first iteration define /ones "ased on the handling units& one for each handling unit. These /ones can "e further modified or split in su"se)uent iterations "ased on product activit# in the /one "ut without changing the storage media constant. *n most cases it is useful to split a /one into separate forward and reserve /ones. The assignment of product groups to storage /ones affects process plans. The simplest process plan in one in which an entire group follows the same path. A comple% plan would have fraction+s, of the group following different path+s,. (imple plan: receiving Comple% plan: receiving pallet storage pallet storage carton retrieval carton retrieval *tem retrieval shipping shipping

Level * Storage +e ia )ssignment to (ones" (one Si,ing Assign a storage medium to each /one& eg. (ingle deep pallet rack& (helving. (ince storage medium and product groups are assigned to a /one the si/e of the /one can "e determined +in terms of aisles and racks,. The user has to choose standard storage medium si/e to accuratel# estimate the /one si/e. The different storage media t#pes with standard specifications are assumed to "e availa"le to the user while making the decision. Level - Storage assignment" or er pic& met.o " accumulation an sorting

This level included a large num"er of decided which reflects the operational efficienc# of the warehouse. (torage assignment methods like dedicated storage "ased on (=> num"ers& activit# or shared storage "ased on class are specified. ?etrieval methods are specified in conjunction with the storage methods. ?etrieval methods include sort8while8pick +(W7,& single8order8pick +etc,.

Accumulation and sorting decisions are impacted "# /oning& time windows and order retrieval decisions. The situation resulting from other decisions decided accumulation and sorting methods. /valuation After level 2 decisions are made the performance of each function and the design of each su"8 pro"lem is evaluated. The paper does not mention the e%act anal#sis techni)ues or methods to use "ut shows possi"le wa#s to evaluate each su"8pro"lem design and check for consistenc# in the workflow. The design is evaluated relative to constraints imposed "# availa"le space& la"or& order pick time& "udget& operating cost& etc. The authors have also provided remedies for infeasi"le or inconsistent designs. The remedies are descri"ed for instances in which the design is violated. This list is not e%haustive and onl# suggestive while it remains to the user to choose the most suita"le remed# A warehouse case has "een used to illustrate the proposed warehouse design workflow. The design process in iteration 1 is kept as simple as possi"le and then improved on in su"se)uent iteration after careful evaluation. We will not "e descri"ing the e%ample case here "ut the designs we have developed for real warehouse cases are presented in this report

T'( T()A# *++T CA#( !01ective: Te%as 0oot& a "oot manufacturer ships its "oots a warehouse in $eorgia where the# are sent to customers all over (outheast >.(. The# are "uilding a new facilit# that would start operations in 2 #ears. ata is provided "# Te%as 0oot design their new facilit# and also redesign their e%isting facilit# to improve productivit# in the face of uncertain demand. Target is to make the facilit# highl# efficient and fle%i"le to allow operations to change with "usiness changes. Current Process Plan: ?eceiving 2iven Data: *n"ound (orting put awa# 7icking 4ut"ound (orting (hip

Storage

/quipment

1ach carton +l % w % h, @ +-A % 1- % B, 1ach "undle @ D cartons high 1ach "in shelf @ - "undles high 0in (helf +l % w % h, @ +1-A % -A % 22, !perating policies 2 da# week - shifts (hift 1 picks orders (hift - restocks shelves

Manual 7allet Cacks 0alding Machines Tuggers

Pic&ing met.o 3o order preprocessing (ingle order pick +(47, 7icking in shift 1 starting E a.m.

*n addition to the a"ove data *nventor# Master& *tem Master and 4rder Master for two months of data was provided. The warehouse handled similar cartons. (ku!s are received in pallets "roken down in the in"ound sorting to "undles and stored in shelves. 0undles and items are picked from "in shelves and forwarded to out"ound sorting area. More than 1AAAA different (ku!s are handled. The Master data files provide re)uired data to come up with a suita"le warehouse design using the warehouse design workflow +W W,. We will descri"e the design procedure in detail. As suggested "# the workflow we worked in an iterative manner& improving the design in su"se)uent iterations. We have this case in three iterations. *teration 1 was made simple as recommended "# there workflow. After the iteration was completed there were numerous possi"ilities to change the ..3 and hence the design. The workflow!s recommendation to keep the first iteration simple is to open up more wa#s "# which the design can "e improved in the second iteration. After each iteration the design was evaluated and necessar# changes were made in the ..3 to reflect the changes in the design. 0# design& what we mean here is not the entire la#out as specified "# the W W "ut mainl# the storage media t#pes& aisles& pick methods& dock anal#sis. The la#out was difficult to determine without "eing given the construction area la#out. The design decisions were mainl# influenced "# product and order profiling. As we progressed with the design su"8pro"lems according to the workflow& we used the ta"les that were given in the research papers to organi/e the project. 1ach su" pro"lem had specific ta"le+s,. 'ater in the process most of the categories in the ta"les were not "eing used at all or were unnecessar# for an# specifications or further anal#sis as far as this case is considered. (o we came up with ta"les& few of which are modified and others are new. We recommend a warehouse designer to consider these ta"les to "e "asic and e%pand the necessar# categories depending on the comple%it# of the warehouse processes. The ta"les are provided in the appendi%.

.or anal#sis of data"ases (6' )ueries in M( access were used while ta"ulation and calculations were performed in M( 1%cel. Workflow diagrams were prepared in M( 1%cel. We have provided a "rief description for ever# su"8pro"lem in each iteration supporting the assumptions and choices made.

Te,as *oot - .teration 1 Level 1 - Function Flo% Net%or&: The .unction .low 3etwork for the first iteration is taken to "e the simplest possi"le one which encompasses all the flows in the s#stems in the simplest wa# possi"le. (ince in our case the handling units into the s#stem are 0undles +cases, and those out of the s#stem are either 0undles or Cases& the following ..3 is devised ?eceiving *n"ound (orting Level 2 - Pro uct an 0undle (torage !r er Profiling *tem ?etrieval 4ut"ound (orting (hipping

The 7roduct 7rofiling in this case is the simplest one possi"leF as all the (=>!s falls into the same categor# and within this an GA8-A classification can "e followed to store products within the aisles. This data is from the *nventor# (napshot and the (=> Master

Product /roup :andling units 3um"er of 7roducts Cu"eH*tem *temsH0undle Cu"eH0undle

/roup 1 0undles in 8 0undlesH*tems 4ut I1DA.A1D D A.AIB

Ma%. inventor# cu"e per product Ma%. inventor# cu"e for group The dimensions of the :andling units are :andling >nit *tem 0undle Width 11'ength -A -A :eight B -B 3o. of >nits 3A D A.ED2 EA1J.2

4rder profiling for this *teration remains prett# much the same for all the iterations& as we are concerned onl# with the num"er of (ingle and Multiple line orders for the same set of data from the 4rder :istor# Ta"le& which is the same for the given set of data.

+rder #i$e (ingle line order Multiple line order

Total 1BIGG JEE-

Doc" Anal%sis The data re)uired for this part of the workflow is the order replenishment histor#& e%pected order e%ecution times and e%pected service time per order. :ere& service time is defined as the average time it takes to loadH>nload products at the dock. 4perating 7olicies of the warehouse are also re)uired for this step

Total 4rders 4rdersH da# (ervice hoursHorder Total (ervice Time Working hoursHda# Time Window 3o. of docks

1GDAI IJA.B2 A.AJJ JA.EA G B G

Level ' - Pro uct )ssignment to (ones The different /ones into which the warehouse has to "e segregated is done in this step& which depends mainl# on the .unction .low 3etwork. $roup 1 is assigned to 9one 1 ?eceiving *n"ound (ort 0undle storage *tem retrieval 4ut"ound (ort (hipping

Level * - Storage +e ia )ssignment to (ones (torage Media to "e assigned to /one 1 is chosen& "ased on the ph#sical dimensions of the unit of handling to "e stored.

'eight 2one 1 9one 9one 1 7allet ?ack (torage Media 7allet ?ack (lot :eight 2A ims epth B2A

Depth BWidth 2A

0ength1Width 2A (pecs - deep

Level - - Pic& +et.o 7icking "# cart is proposed and "atching of single line orders is allowed. 4rders a"ove -A lines are to "e picked separatel#. /valuation As a ver# large "ias e%ists in the num"er of units ordered& it makes sense to partition them into groups depending upon their annual sales. (toring the products two deep doesn!t make sense as most of the products have onl# one pallet in storage.

Te,as *oot - .teration & The same steps as a"ove are followed& with suggested improvisations from iteration 1 to the .unction .low 3etwork Level 1 - Function Flo% Net%or& The function flow network is changed from the previous case "# splitting the previous flow into two parts as suggested "# the evaluation for iteration 1. 0undle (torage 0undle (torage *tem ?etrieval *tem ?etrieval

?eceiving

*n"ound (orting

Accumulation

(hipping

Level 2 - Pro uct an

!r er Profiling

7rofiling in this iteration is done "# plotting the cumulative annual sales percentage over the (=>!s and products are profiled according to the GA < -A rule +i.e the top -AK of the (=>!s which account for GAK of the sales, are segregated into 1 group and the rest are separated into another.

Percent 120 100 80 60 40 20 0 530031083 530069415 534158602 394132111 5K77DC 493043 179022 691080 262658 695917 691821 691456 81-2000 1101960MA 302558MA 313649MA 92530MA 555509 94443 694532 495521 791096 93324 691391 710053 690933 1932 499603 1917 496894S Percent

To o"tain the a"ove graph& sku and anuual sales from the *tem Master is used. The (=>!s are arranged in increasing order of their Annual (ales and the Cumulative Annual (ales 7ercentage of each (=> is calculated. The Cumulative Annual (ales 7ercentage and the corresponding (=> are plotted in the graph as shown a"ove. .rom the a"ove graph it is clearl# evident that a ver# small percentage of (=>!s contri"ute a lot to the annual sales. (plitting the (=>!s according to this rule& the following Ta"le can "e arrived at.

Product /roup :andling units 3um"er of 7roducts Cu"eH*tem *temsH0undle Cu"eH0undle Ma%. inventor# cu"e per product Ma%. inventor# cu"e for group 3nit 0undle *tems

/roup 1 0undles in 8*tems 4ut JAGA A.AD A.AI I.JE -GGD-.2A Width 11-

/roup & 0undles in 8 *tems 4ut DAGA.AD A.AI A.2I J2I1.AG 'eight -A -A -B B 3nits 3A D

0ength

As far as 4rder 7rofiling goes the same method is followed as in the previous iteration& onl# difference is that there will "e - groups in this case

+rder #i$e

/roup1

/roup&

Total

(ingle line order Multiple line order

1AGB1 -JGA

B1BE 1JI-

1BIGG JEE-

Doc" Anal%sis ock Anal#sis is the same as the previous iteration "ecause the average loading time per order is not given and hence& a suita"le value of - minutes per order is assumed. Level ' (ones" Pro uct assignment to storage ,ones The Warehouse is divided into - different /ones each for a product group and a group assigned to one Level * Storage +e ia )ssignment to (ones an The storage media to "e assigned to each /one is decided "# the si/e of the handling unit 2one 1 2one & Product /roup (torage Media 3um"er of 7roducts Avg. :andling >nitsH7roduct Ma%. :andling >nitsH7roduct L :andling >nits (tored 7ick 'ocations for $roup :andling >nitsH(torage >nit .loor (paceH(torage >nit +m-, (torage >nits 3eeded .loor (pace for $roup +m-, 1 7allet ?ack JAGA I.JE 1G.EB -GGDJ BGG2 BG 1.AD -2E BJJA 7allet ?ack 7allet ?ack & 7allet ?ack DAGJ.1J D.-D 1IA-J 2E2J -B A.2J DGJ -GGB 'eight 2A 2A Depth B-0ength -D -D (one Si,ing

The num"er of pick locations for the group is calculated "# summing up all the storage locations that are needed for each (=> +"ased upon its Ma%. *nventor#, Level - - Pic& +et.o The same picking method as that of the previous iteration is used and the same "atching policies are continued. /valuation .urther segregation of group 1 into a forward storage area and reserve storage area is proposed to facilitate "undle picking and item picking.

*RA/ The 0?A$ case was a "it more complicated when compared to the Te%as 0oot case& in the sense that there were three different cartonHcase si/es ' This made it a challenging task to design the warehouse appropriatel# using the Warehouse ifferent case si/es in the 0?A$ case *nvolvement of a third 7art# warehouse Top 12K (=>!s go directl# as pallets into the 0?A$ warehouse and the rest to the J7' from where the# are shipped to the 0?A$ warehouse 0?A$ is a forward storage for the products in J7' and contains J da#s! suppl# esign Workflow. The main differences "etween the 0?A$ case and the Te%as 0oot case are:

Taking the a"ove points into consideration& the workflow has "een implemented to the case& in a similar wa# to that of the Te%as 0oot case. Function Flo !et or"

The function flow network for the first iteration was drawn in the simplest possi"le manner& handling units received and shipped are taken into consideration and the "asic network which can "e designed to sustain this flow is devised. .or the first iteration& 0?A$ warehouse has a pallet in"ound sorting area where the mi%ed pallets received from the J7' warehouse and the full pallets received from the vendor are "roken up and stored as cases for item retrieval. This will "e improved later on in su"se)uent iterations. Product and +rder Profiling The product profiling is done in a similar wa# to the previous case& with a slight modification& to incorporate the J7' warehouse. .rom the *tem Master and the inventor# snap shot& all the products with annual sales or on hand inventor# greater than /ero are short listed. These are then plotted onto a graph with (=> on the ; and annual sales on the M a%es respectivel#. The top 12K of the

(=>!s are then allocated to the 0?A$ warehouse and the remaining G2K are allocated to the J7' warehouse. *n the first iteration& all the products are stored in a single /one. 1%cept that in the 0?A$ warehouse a reserve area for the top 12K (=>!s is allocated "ut all the (=>!s have a place in the forward area. Anal#sis of the first iteration suggested a classification of products "ased on case si/e in order to reduce the overall area re)uired for the warehouse la#out& hence products with similar case si/es are profiled into the same group resulting in three groups for three case si/es. With feed"ack from the second iteration& further profiling is done in the third *teration with similar product groups "eing classified into separate groups. As far as order profiling goes& the data from the order histor# has "een segregated into orders with multiple lines and orders with single lines so that order "atching can "e done at a later stage to facilitate order picking. Doc" Anal%sis ock anal#sis for this particular warehouse is done "# taking into consideration an appro%imated value is used for the service time +here service time is defined as the average time it takes to load the truck,. The total num"er of orders in the given time period is taken into consideration and average num"er of orders per da# is calculated. :ence& the e%pected total service time is arrived at and the docks are calculated& depending upon the operating policies of the facilit#. A "etter estimate for dock anal#sis can "e arrived at "# calculating the e%pected order completion time for the warehouse. 2one Classification The warehouse is now classified into appropriate /ones& depending on the function flow network and the forward and reserve areas re)uired for the warehouse. .or the first iteration& the /one segregation has "een prett# simple& with - /ones in the 0?A$ warehouse& one for the forward storage with all the product stored there and one for the reserve where the top 12K (=>!s are stored. .or the second iteration& depending on the ..3 and the product profiling& B /ones were created& one for "ulk storage of product and J /ones depending on the si/e of the cases. #torage Media Assignment to 2ones 0# far this has "een the most important and complicated step of the workflow. *n order to arrive at this& the on hand inventor# levels given in the inventor# snap shot are scaled up a factor to account for the ma% inventor# position& in our case it has "een chosen as 1.2. According to the /ones which have "een defined in the previous step and the ..3& the appropriate storage media is assigned to the /ones.

The footprint of the storage media in the warehouse is calculated in the following wa#: The standard dimensions of the slot si/e are chosen from the (torage Media Master and from there on the (umber of Slots )S* re)uired for each storage /one are calculated depending upon the Ma% *nventor# and the (lot imensions. 4nce the (umber of Storage slots)S* of a t#pe for a /one are calculated& the (umber of +ays)+* is calculated +in terms of num"er of racks on top of each other or +ay ,eight )-*, 0 @ Ceiling+(H9& 1, .rom the standard dimensions& the .idth of each rac! ).* and Depth of each rac! )D* is taken and the Total length of bays)T* is calculated T @ +0NW, A standard &ength for each aisle)&* is assigned to each /one and total (umber of Storage Rac!s)R* is calculated ? @ Ceiling+TH'& 1, 4nce the num"er of storage racks is known& the (umber of /isles )/* is A @ Ceiling+?H-& 1, 3ow& an appropriate /isle .idth )/.* is assigned to each /one and the Foot print )F* for each Storage Rac!)R* is calculated . @ +AWN',O+'N , .rom .& the appro%imate Footprint )-F* for the /one is 9. @ .NA The a"ove procedure is repeated for each /one and the total Floor Space).F* for the warehouse is W. @ P+9., *teration 1 3um"er of 9ones Aisle 'ength .loor (pace *t is seen clearl# from the a"ove ta"le that the floor space in su"se)uent iterations is decreasing which proves that a "etter design is "eing achieved "# the workflow approach. Pic"ing Method 7ick "# cart is chosen as the picking method and single order picking is followed as far as possi"le. The design which is arrived at "# following all the a"ove steps in se)uence is then evaluated with respect to the recommended parameters and necessar# changes are incorporated se)uentiall# into the ..3 in that all the steps are followed through again and final feasi"le design of the warehouse is arrived at. *teration *teration J