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Storage and Maintenance

Professor Xavier Gavaldà

Made by:
Jorge Silva
José Queiroga


Introduction 3
Problem Description 4
Stock and Storage System Analysis 5
Shelves Layout 5
Analysis of Movements 10
Analysis of the Number of Rolls and Dock berths 10
Áreas de Entrada e Saída 11
Warehouse Layout 12


In the Storage and Maintenancesubject, it was given us the task to draw a warehouse layout, with capacity to store three types of food, with distinct storing requirements.
With this work we hope to improve our knowledge in storing subjects, and gain a better perception with the difficulties that will be ahead of us in the real life, regarding this king of problems.

Problem Description

We have a food warehouse. The foodis divided in three categories: frozen, fresh and dried food. All the categories of products possess two different types of boxes that they differ in its height. Inside of these categories diverse references of products exist that can according to be divided in two classrooms of rotation law of Pareto, that is, 20% of the references correspond 80% of the sales. We will now go to describe therespective characteristics of the categories being as the flow amounts, stocks, type of storage and restrictions of storage.
In first place we have the frozen ones, these have to be conserved in temperatures between -30ºC and -20ºC during all the processes that they will suffer inside the warehouse (cold chain), this imply, as it was to predict, an increase of storage costs. In this category we have1200 references with a flow of 24000 boxes per day, as much of entrance as of exit. The storage possess the capacity of supplying of 6 days (number of days that we have products enough to satisfy the demand).
In second place come the fresh ones, these have to be conserved in temperatures between 0ºC and 6ºC. In this category exists 3000 references with a flow of 92000 boxes per day, as much ofentrance as of exit but this time with the supplying capacity of 4 days. In this category we have to be very warned about the period of validity of the products that is very short due to proper nature of foods.
Finally we have the dried ones. This time they have to be conserved in temperatures between 10ºC and 25ºC, that is, to the ambient temperature what it makes the products with less expensesassociates. In this category there are 1500 references with a daily flow of 40000 boxes of entrance and exit. Its capacity of supplying is 8 days.
In all products is followed the FIFO criterion, and it’s considered that the maximum weight of the box is 18 kg.
Relatively to the warehouse is imposed to us a maximum height of 8 meters and the existence of pillars of support, of 400 mm for 400mm, in each 12 meters, as much in the vertical line as in the horizontal line.

Stock and Storage System Analysis

To begin, we will start to calculate de stock, using the range given.
| Range (days) | Daily Flux | Stock |
Frozen | 6 | 24000 | 144000 |
Fress | 4 | 92000 | 368000 |
Dried | 8 | 40000 | 320000 |

As said before, with a Pareto Analysis, there are Class A products thatgenerate 80% volume of boxes, being the 20% remain generated by Class B.
| | Ref. | In /Out | Stock | Big Boxes | Small Boxes |
Frozen | A | 240 | 19200 | 115200 | 80640 | 34560 |
| B | 960 | 4800 | 28800 | 20160 | 8640 |
Fresh | A | 600 | 73600 | 294400 | 206080 | 88320 |
| B | 2400 | 18400 | 73600 | 51520 | 22080 |
Dried | A | 300 | 32000 | 256000 | 179200 | 76800 |
| B | 1200 |8000 | 64000 | 44800 | 19200 |

Shelves Layout

For the next step, we have the creation of the sketch related to the box position on the shelves. The different constraints are included on the suggested picture.
Firstly, it was designed the top view.

Initially, it was defined the profundity of the shelves. We decided just to have one box depth, due to the FIFO requirements and...
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