INTRODUCTION TO WAREHOUSE OPERATIONS NIPPON EXPRESS CO., LTD.Introduction In response to economic globalization, sales areas and business fields of ‘Nippon Express have been expanding throughout the world, Particularly, along with the development of overseas warehouses, ‘warehouse sites are being equipped with multi-logistics fimetions, such as material handling, storage, distribution processing, information management, transportation and distribution, as the core of integrated logistics businesses. In order to respond to customers’ various needs in the future, it is necessary to develope human resources, mainly warehouse personnel, to strengthen these logisties functions. Based on actual situations, this Manual has been compiled in English as aan overseas version of the original manual prepared by the Operation Department of the Headquarters, so that operation managers and sales representatives at warehouse sites will be able to leam the basics of warehouse operation management and enhance operation efficiency, quality control and safety across the board. To overcome the competition for customers with the world Logistics Service Providers, you are requested to utilize this Manual to actively promote various proposals to customers including suggestions for improvement.Table of Contents Chapter 1 Basic Operation Design Section 1, Warehouse Internal Layout. 2 11. Areas and fnctios. 2 2. Layout ofthe areas. 2 3 A. Positioning of warehouses as dstribution center nd Is fanetons 4 s 6 9 'B. Basic layout ofthe entice distbuton center CC. Layout ofthe are inside he center: Space distribution cach area ‘A. Cleulting the space required 0 B. Calculation examples (based onthe concept) 0 4, lnsalation of iss 16 A. Types ofalses 6 B. Deciding the working ssl width ” Section 2. Stacking. 1. Base of plletizng - 23 A. Pallet stacking method 23 B. Pallet height 24 C. Types ofpallets 2s 2. Stacking the plletized cargo - 30 A. Ditect stacking 30 1B. Types and selection ofstrageequment 30 8. Stonge of ron palletized cago 4 ‘A. Case goods nd piece goods 3 B. Selection of storage equipment (cos-benefit perfonmance) 37 CC. Flexible container bags 40 D. Leng goods 2 . Bulk cargo 2 4 Floor suength, wall tenth and eetive height 43 |A. Deteonining the Noor eng 4 B._Suength of the framework and outer wall ofthe warehouse 4“ CC. Detemination ofthe effective height Section 3. Preventive Measures for Load Collapse... 1. Pallesied cargo 2. Racksored cargo : 31 ‘A. Rack and self fl preventive measures: si 'B. Measures to prevent fils fom the rick 3Section 4. Location Management rnin 11. What ie action management. 2. Setting the Joatonnumbet ‘A. Notes for setng the location number BB. Lecation mmberstucture 58 Seting method 39 8. Types of location management nn ‘A. Operation method by fixed location 6 1B. Operation method by relocation: 2 C. Double transeton method 6 D. Merit and demers 63 “4. linroduetion of improvement efforts 64 Section S. Picking Methods, 1. Tota picking ~ 2. Single order picking 8. Compariton ofboth method and selection et anne 4 Specific operational procedure. ~ a ee 7 BB. Picking indication method (C. Buamples ofthe pickiag methods Chapter 2 Storage Operations Section 1. Quality Control of Stored Carg0nvennninnnnnnnnnn 1. Quy aston prevent mews y temper thant com A. Necessity of temperature and humidity contr 3. Measurement oft empertie an hig C. Humidity control ease D. Managemect of ai condioners 2. Asia, anthinsot and antbird measures. ‘A. Messures for damage eased by 1a 1B. Measures for damage caused by insects C. Measures fr damage caused by bids 8, Measures forrin storms and high te. ‘A. Aepated damage: . Preventive measures (presauions) 4. Fre preventive measures... - ‘A. Anticipated damage smn 31 1B. Fire preventive measures: nnn 31 8. Dus preventive mess4E8 16 8 80 83 84 84 87 2 90 90 90 31‘A. Antspatd damage: 98 B. Dust preventive measures 94 6. Antiodor messus.. 96 A. Mixed storage evading cargo 96 soo ” 100 100 1B. Antsodor measures» sm se 7. Handling precaution acording tothe charactors of the store ca30 ncn AA. Dangerous goods : 1 Designated combustibles C. Fire-fighting inhibitory substances (regulated) 8. Posthandling. Section 2. Inventory Managemen ofthe Stored Cargo 1 Basis of aventory management... |A. Physical inventory and theoretical inventory 108, 'B. Preparation of tags 7 108, CC. Prepution of storage ledger 109 . Comparing wih th customer's management ledger 109 2. Inventory ehh ng nnn 108 A. Purpose of inventory stocktaking 109 B. Problems of inventory stocktaking: 110 CC. Stackaking metods au D. Implementation method 2 EE. Specfe procedure for stocktaking 13 Chapter3 Cargo Handling Operations ‘Section 1. Receiving Operations... at 1, Preparatory operations 12 ‘A. Underage cg sce oe eve Adan Stig Noe (ASN) e121 1B, Arrangement offers and fori operons 126 C. mangement of tools sich as pallets end rol boxes 134 2. Receiving operations (operations cn the receiving dy) 1s A. Guidanoe of eriving vehicle: 136 B. Unloading 136 Receiving inspection ~~ sola D. Receiving and puta 131 , Preparation of storage ledger and rac cards 153, Section 2. Shipping Operations sone SA 11. Preparations for shipping 154‘A. Understanding of the cargo information scheduled tobe shipped (ode) 154 2. Shipping option a son 186 ‘A. Stipping by pale 136 BB. Shipping by caronipcce : seoninnnnnnnneennn SP 8. Picking operations... 157 A Chae sion og ith ig apn oy 158 BB. Shipping inspection Shinn 160 C. Packaging operations 161 1D. Sorting opetions senna B. Transfer operations rissa 165 4. Loading onto tusks. ~ sa 16 ‘A. Check and confinnation of goods sna 66 BL Check of the hand-oversssnseunnnnnnnnnnn 167 C. Acknowledgement check afer leading 167 D.. Response oiregulariy sennnsnonennnnnns 167 '5. Procedures afer shipping, ~ 1 A. ing tps) nition ss sec Y B. Orgnizng, lerng and making space Section 3 Distribution Processing Operations. 1 Importance of disruon processing peaons. 2. Tes af dabon pose cps ‘Weeping and packaging Assring Repeckin. Sop Basing Lieling and ashing Prot inspection “~~ Assenbing (Catng and ring aching rice tgs Repucking bows Sertng ot Tnpatig infomation Funigation Examples fines neon lock 9 Royse ining ion psig pin [AL Huan sure arpest 1B. rely aspect: ZEr Ree R OME ORE. Equipment sepect 186 . Qualification spect 187 4. Notes for distbtion processing operations. Section 4. Utization of KPI 1, Outine and noessiy of KP int 8D ‘A. Whatis KT? ST 1B. Mis of tlizing KPin ogists: 189 2. Ove picure ofthe logistics KPI es 3. Definition of pica! KP in logisuties management .n.nnnnnnnnnn 1D Chapter 4 Safety Operations Section 1. Management Based on “SS” and “3 Theorems”. 11. Outline of SS actives and theorems. 2. Specific on-site approaches A. Sorting B. Seting-in-order C. Shining D. B ‘Standardizing ‘Sustinig the dieiptine =~ Promotion of visualization a Section 2. Basie Knowledge of Safety Operations 11 Occurrences of indus accidents inthe warehousing indoty andthe featues...200, A. Types ofindustil accidents 200 1B, Oscuroncae by causal agent 201 Causes of accidents 201 2. Improvement ofthe safety management st. 202 ‘A. Appointment of safety managers, et. 202 B. Chief worker 202 8. Confimtion of work envionment manaseme cnnnnennnn 203 A. Bsleor 203 'B. Work oor soiniiininnniniinniinnnininnninnnnne © Airvolume 203 D. Ventilston 203 B. Lighting er eerineneuninninnnnstnnnninennnnsn 203 4. Basi items fer safety operon on 204 'A. Notes for ary operations in warehouses ssn 204 'B. Essential points of cago-handling operations 204 (C. sent! points of manual cargo-handling operations 204Preston for fil machines enn 208 B. Placing safer signs sens 205 F, Safty operation in high places =n 206 G. Safe in oer special operations 207 5. Qualification equtements for safety operations... sens 207 6. Safe nmpetion of machines and 08mm 207 A. Type oft inspections 207 7. Safety protetve gear. 9 eh ee 209 1B, Safety shoes se 208 ©. Safey els —— 210 D._ Work gloves: : 2a 8. Hlevaton facies, 212 AL Mobile Inder an B.Stepladders eR 9. Safety operations proces enn 212 ‘A. Operations requiring the safety operations procedures 213 1B. Notes fo preparing the stey operations procedures 213 10, Safey activities. on 213 ‘A. Danger prediction atv 214 'B. Finger pointing and ea sannnanennninrn BLA C. Risk assesment activity Section 3. Safety Operations of Forklift ais 27 1. Management knowledge for using FOS nnn BND ‘A. Restitons on employment smn 217 'B, Pre-operation inspection and period vont inspections 217 C. Preparation of operation plans andeppointment of supervisors sewn B18 2. Precautions fr fri operations, sen 219 A. Precnition before starting forklift operations 29 'B. Precautions fo ving folie 220 (C, Prestution for handling ergo with frklifs 22s D. Precautions before completing okli operations 08 8. Example onan noi pens : 226 ee 26 BL Callison rs eal (C. Cuashes and fs: smn 28 re 29 Flying and ops sree 30Basic Operation Design To master the basic operation designing methods required for exhibiting the logistics center functions | "Toei saccosstuly emi the warehouse funcions and enebiean ‘efficient cstibtion centey, tls necessary to learn the strecute and cargo |) ow ines ofthe warehouse, such 2s receiving and shipping docks, intemal || layout ofthe warehouse, selection of material handing localon | management, picking method, and so en ‘This chapter i ntonded to help you master the basic operation'designing ‘methods and make use of them in efforts fo review and improve curent | \ operationsSection 1. Warehouse Internal Layout Warchouse internal layout refers to allocating the warchouse internal space to manufacturer’ distribution center, < 2 > wholesale distribution conter, and < 4> retail DC center. On the other hand, since < > retail TC center isa pass-through type center mainly focusing on sorting function, it generally doesnot require the functions such as storage ana picking Source: JILS “Text for Certified Logistics Master Certification Courses’BB, Basic layout ofthe entire distribution center Receiving and shipping docks are allocated depending on the facility structure ofthe distribution center [As shown in the following figure, there re 3 types, Fshaped, L-shaped and U-shaped, by the form ofthe low line. shaped type Receiving dock Shipping dock Leshaped type Receiving dock Shipning dockUsshaped type Receiving dock Shipping dock ©. Layout ofthe area inside the center ‘Once the required functions forthe center have been decided, you shold next consider their layout, ‘They ae si ut inthe order of operation prooesesin principle, but the ayout changes depending ‘nthe stats ofthe receiving and shipping docks inthe warehouse. Lay out eacharea so as to shorten ‘the moving distance othe next operation process (1) Layout for tshaped receiving and shipping It the recsiving and shipping docks are secured on both sides facing each other, as shown in the following figure, each area ean be lad out in an Tshaped lino so that argo will flow lineasly. In this case, loading/unloading from trucks can be independently carried out, and congestion in the truck berth (font yard) and docking berth can be prevented, allowing efficient receiving and shipping operations.‘Manufncrerawholesalealvendors Tit Song Area per soe) i The Retalingindastry Sore) (2) Layout for U-shaped receiving and shipping ‘Structurally, ifthe receiving and shipping docks can be secured only on one side, each ‘area has tobe laid out in a manner that cargo wil ow dhrough in a U-sbaped line. If ‘there is both an entrance and an esit, loadinglunloading from trucks ean be independently carried out, bu the truck berth (front yard) may be congested. If there is only one entrancelexit, receiving and shipping are conducted in the same area. ‘Therefore itis necessary to separste working hours of receiving and shipping but this lowers operation efficiency: For such warehouse, it is also necessary to consider the construction of « now entrances<< In tho case of having both an entrance and an exit> Manufocarers wholesalers vendor Real basins hop) ee a= Sering acaba soe) Cac In the ease of having only one entrancelexit > aires well eto | [Ret bes on) Boring area (pre) (8) Layout for L-shaped receiving and shipping the receiving and shipping docks are lated on the front and the side, instead of wo docks facing each other, each area has tobe laid out so that cargo will ow through in tn L-shaped line. In this case as wel, operation efficiency is lower than that of the Trahaped type. However, cause the entrance and exit are oeated on different sides, receiving and shipping operations canbe efficiently earied out ifthe truck berth (front yard) is lange enough,(4) Intrrelations with each area ‘When you decide the layout of each area, itis important to evaluate the proximity of ‘each area and analyze its purpose. The proximity refers tothe dogree of closeness of distance in the area layout. “The folowing figure shows an example of correlation analysis of «layout 1 [Receiving Storage Picking oceesng Sorting Shipping Offce Workers” 8 waiting room 2 a 4 5 6 7 'a_[Patculary important to beng loser Important to bing closer {High frequency of incoming and outgoing cargo. 2 _[Otsinary frequency of incoming and outgoing cargo [Low frequency afincoming ara [outgoing cargo “g__[Easyt0 instruc witha voucher] land confirm [Congested operations Ordinary proximity 1D |Noneed to bring closer not Important) Not preferable to bring closer * Material prepared by JMA Consulta nc. with additions and coretons 8. Space distribution to each area Distribute space to each area in consideration of the volume and frequency of reeiving ‘and shipping Gtaging) cargo, materials handling mode, storage mode, distribution processing items, number of workers required, operation efficienes, and soon[It i important to periodically review each space in order to respond to the changes of ‘the above operational requirements ‘A. Calculating the space required ‘The following deseribes the concopt of ealeulating the spaces required for main areas Receiving rea Storage aes ‘Number of receiving pallets per day (actual valu or planed vals) ‘Number of temporary steraged pallets = Number of receiving pallets per «ay = Assumed numberof ations ‘Area of temporary. soraged pallets ~ Number of tmporsy-strage pallets sie unit of area (ap) Receiving space = Area of temporary-storged pallets + Area of sises + ‘Area of goods inspection pace ‘Number of shipping pallets per day (sta value or planned vals) ‘Number oftemporry-storage pallets Number of shipping pallets per da | ~ Assumed number orrttions| ‘Area of temporary slorged pales = Number of temporary storage ples ‘ssc unit of area (npe.). Sorting an shipping space = Area of emporrystoragd palit + Are of | isles Ares of lading place Planned inventory by commodity Number of storage pallets = Plamed inventory by commodity ~ Number of items stacked on pallet, [Number f required racks = Number of storage pallets + Number of pallets sacked in ack ‘Area of pallet acks ~ Number of rquied racks x Basic unit of rea (oman) © Storage space = Are of pallet asks ~ Area of aisles for main work = Required with > Dimension ofthe vehicle body docked lengnwise + Minimum tang radius inthe case of he reson Pe) . Calculation examples (based on the concept) (1) Example of calculating the space forthe receiving area < Prerequisites > Receiving vehicles five 10-ton trucks arrive in the morning and another five in the afternoon.‘They unload cargo sequentially from 8:00 and 15:00, respectively ‘temporarily in the reeiving space. Operations are carried out by one forklift operator. Once unloading is completed, hhoshe sorts the temporarly-storaged cargo (goods inspection and sorting) and moves it to the next area, "The workload is reasonable for one day. ‘The 10-ton truck ie a wing-type and entries 16 pallets of T11 type (1.1m x 1.1m), ‘Cargo is unloaded with a S-ton fori ‘The space is calculated as follows under the above prerequisites, Warehousing workload per Gay (umber of | 10-on ruck x 10 16palletsx 10= 16 pals pallets) Assumed naib ofits unter of | oaions (1) ross the temporada) Nonnberoftenporiy-sionged pales [1602 vans = BO ples sonatas 2 Thearea of aisles and that of the goods inspection were sto be 40% ofthe asa of the temporary-storaged pallets. If the rotation is done once, all the receiving cargo of the day will he placed in the temporary storage area. If there is more rotations, it means that the amount of cargo kept in the temporary storage arca will be reduced. Given the prerequisites, if one forklift operator unloads the cargo from the 5 trucks for 2 hours from 8:0, using a ton fori, sorts out the cango in the temporary storage area until 12°00, and repeats the same operations again in the afternoon’ this means the temporary storage arca has been rotated tice ‘The required space varies depending on the operational conditions. For exemple, if arzivals are dispersed, it is possible to sort out the temporarily- storaged cargo aradually, decreasing the amount of temporarily'storaged cargo and increasing the ‘number of rotations. One forklift operator is supposed to carryout the two operato ‘unloading the cargo from the trucks and sorting out in the temporary storage area. ‘The amount of temporarily storagod cargo will be further reduced if two forklift ‘operators are arranged foreach ofthese operations, respectively,(2) Example of ealeulating the storage space In this eas, racks are used to store in pallet unit. + Decision of planned inventory per commodity First, decide the planned inventory per commodity basod on the end-of month inventory in the recent year. In this ease, the annual average value is 1,000 eases, but ‘the maximum value is 1,550 eases in March, The value was sett 1,550 cases. Unit: cases + Caleulation ofthe number of storage pallots If 12 cases ofthe said commodity are stacked in 3 piles on the 1,100 x 1,100mm pallets ofthe JIS Gapan Industrial Standards), the numberof pallets used is as follows. 1,850 cases +12 easepalle 20.2 pallots > Approximately 190 pallets + Caleulation ofthe mumber of racks Racks (2.5 m width, 1.18 m depth and 3 piles) capable of carrying 6 ofthe said pallet is sed 180 pallets +6 palletsfunit= 21 Thunits-> 22 units+ Caloslation ofthe area of racks ‘When installing the said racks, their occupation area also includes the aisles. Suppose the aisle width is 3 motors, and haf ofthe aisle area is added tothe area of one rac. Occupation area of one rad 525 m? 1.15 meters + @ meters» 2} x2 Oceupation area of 22 racks 1525 mx 22 unite = 145.15 m? In the case ofa commodity whose inventory Buctuates greatly, tis necessary to decide the planned inventory by commodity in consideration of not only endofmonth inventors, but also the maximum inventory of one month.(3) Required space forthe truck berth ‘The required space for the truck berth differs depending on the docking method and the size of the vehicle The fll length ofa combination vehicle is approximately 16 m for ccean containers. When docking a 409. container lengthwise in the docking besth (aised Moor) a shown in the figure, an 182 metors or wider truck berth (front yard is required, [Combination vice camying 40M oean container] In the case of an 11 ton truck with fllTength of approximately 12 meters.as shown in the figure, the truck berth (Gront yard) needs a width of approximately 22 meters or more, Likewise, in the ease of a 4-ton truck witha fl length of 7.8 meter, the truck Dt (front yard) neods a width of 19:2 meters or more.[irton truck) In the eae of an 11-ton truck with a bed length of 97 m (exazaple) [4m tuck) * The full length ofthe combination vehicles is approximately 12.4 for a 200 ooean container and approximately 16.1 t9 16.4 meters for a 408 ocean container. When docking tho truck alongside a low-floor warehouse to unload the eargo as shown in the figure below, the truck berth (front yard) needs a width of approximately 7 to Smeters. 1s4. Installation of aisles ‘The aisles in the warehouse need to have sufisient space for efficient receiving and shipping operations, safe passing of workers, inventory stocktaking, daily inspection, ‘and 60 01, It is also important to flexibly change the installed aisles, without ‘immobilizing them, according to the flow and storage condition of cargo. A. Types of aisles (1) Main working aisle ‘This isthe widest aisle among others and sai to be the main artery of warehouse operations. If cis isle is obstructed, overall operations are alfcted. Accordingly it is important to set this aisle linearly so as to allow safe and efficient transfer with a complete view of the storage area, For frequently hanaled earg, the working aisle may be set aa one-way in order to prevent crossing of forklifts in the aisle. Bey ay Darran sromse pressing =(2) Subworking aisle ‘This is mainly intended for picking operations and is set narrower than the main aisle, If ths is too narrow, however, pushcarts or workers may come in contact with racks, te., obstructing operations such as picking and cargo inspection. I this is too wide, it means that the storage space is reduced (3) Pedestrian pathway Because forklifts move around inside the warehouse, it is important to allecate an ‘exclusive pedestrian pathway to ensure safety. In order to indicate this asle, draw a ‘white or yellow line on the floor to prohibit forklifts from entering beyond the line (fit is inevitably necessary to enter, stop once and drive slowly). Specie paces include the centrancolesit of the warehouse, where itis kely to come in contact with forklite ‘around the elevators or doors of the warehouse, inthe aisles to the office and the suardroom, where many workers and clerks pass, B. Deciding the working aiste width kis necessary to consider the with of isles carefully, because it hasan effet on operation efficiency and storage ficiency (1) Wiath-deciaing elements Materials handling equipment (reach type forklifts, counterbalanced handlifs, pusheart, et.) used atthe site + Types of storage facilities (rive-in racks, electric mobile racks, ete) *+ Cargo londing/unlonding methods (menval materials handling forklift operation, rane operations, ote) + Condition of stored cargo weight, volume, vulnerability, ete) Management. propertios of stored cargo (quality control, lot management, ‘manufacture date management, ete) Specifically, i i necessary to consider por storage place, i and pallets, storage areas for racks(2) Setting the main working aisle ‘The main working sisle is mainly intended for forklift operations. The standard forklift width is 1,100 to 1,200 mm. Suppose two forklifts with a 1,400 mm-wide pallet ‘pass each other, the minimum width required is 1,400x2= 2.800 mm, Given the room ‘width for passing, which is enuivalent to half the width of the pallets used, the aisle ‘width is 3,500 mm, In a warehouse with low materialhandling volume and low rceiving/shipping frequency, however, the width for ono forklift may be enough forthe ‘main working isle. As mentioned above, the width ofthe main working aisle shouldbe set according tothe ‘width of the forklift, width of the pallets used, shape of cargo, skill of the forklift operator, and soon. * Decide the room width in consideration af the ail ofthe forklift operator. torege sees Aisle wi $3800 4,000 mm(3) Sotting the sub-aiste 12 Storage rack area (Setting ofthe aisle for passing ofthe pushcart) Although the cargo is manually brought infout, the aisle width should be set with some ‘extra room because handlifs, pushearts, ete. are used for replenishment and onder picking ‘The standard pusheart width is 600 mm. Adding 300-mm of room to this for operations, tho width required is appreximatsly 800 to 1,000 mm. Ase width 900 (01,000 'b. Storage rack aoa (Seting ofthe aisl for driving forklift straight) ‘When driving a small forklift (reach type 1to 2 tons straight in the storage rack area, the aislo width required is approximately 1,500 to 1,600, adding the 400mm room ‘width tothe forklift width of approximately 1,100 to 3,200 mm.©. Storage rack area (eating ofthe aisle allowing loadinglunlosding with the frklit) When using a forklift for bringing ivout the eargo into the rack, an aisle width Gight-angle stacking width) that allows reasonable right angle stacking is required. ‘This aisle width is decided aceoeding to the outer turning radius ofthe forklift, length of the cargo, required room of the aisle, and eo on, Although itis described in the manufacturer's specifications, it is normally approximately 2,700 to 8,000 mm for the 115 ton reach type fori(Cateulation formula for counterbalanced forklits) Practical right-angle stacking aisle width (A) = Outer turning radius (R) + Drive axle conter line and load spacing of the forklift (front overhang) (D) + Length ofthe cargo (L)+ Room required for the aisle (©) *Porklit tuming diagram gr a A: Aisle width required for rightangle stacking B: 1/2 of the forklift width + inner wheel turning radius CC: Room reawired forthe aisle 1D: Drive axle center line and load spacing of the forklift R: Outer turning radius L Length ofthe cargo We Width of the cargo (Example) In the case of Mitsubishi Heavy Industries’ forllift FB2OP, rated load tons * With the 1,100 mamlong x 1,100 mm-wide pallets compliant with the JIS, a ‘theoretical value plus 200-mm turning room rocults as fellows in the case of W <2B, 10 mm (L) + 200 men (C) = 3,675 mamReference) Aisle with by the pe of Frit Workers, pusbearts_| Working ise wih [0910 1.0 meters Countrbanced| Lato LS meters ovis or [Reach Sto Lome (5102 ons) unterblaneed 3.1103 9meters Riaheangle sting with TR a ‘Summarized from the specifications of Miteubishi, Komatsu and Toyota. Checking the specifications is necessary because the aisle width differs depending on each smamufacturer's model + Coffee break {Find the main specs from the specification ofthe forklifts ¢ Main diensions ‘Main specifications of the reach type forklifts NeneSection 2. Stacking “Stack” refers toa collection of cargo piled up in a warehouse, shed or eange depot in fonder to store, temporarily store or inspect the bagged or eased goods. “Stacking operations” rofer to regularly piling up or bringing down these “stacks” in a certain Single-deckiwo.way <2>Nonteverible wooway <3> Reversible osway QGP G Nonteversiblefourway <5 > Non-evesbesingle-ing <6> Reversible mui oworway swonwayDifterences among the Single deck wo-vay | Thspllet ha nly top deck board ands generally nat sacked] vith cargo loaded [Nonreversibe ‘This allt has deck boards on bt sides and they ae spaced wornay ‘wider atthe bottom. Cargo is generally loaded only onthe op dese Since the boom side lo has deck board, hough ey. |, are spaced wider apr, the pllet an be stacked in a couple of les with cargo Toad, In the case of begged goods, te care Should be taken not o damage them. Revesible worvay | This pallet has deck board on bot sides, allowing argotobe | leaded on ether side often, Vaio tyes of ergo oad ‘Non-roverible "Noneveribe pallet having the fork insenionporsin four |g four ircctions rot rea, ght ad et Non-reverible "Non zeversibe pall ving op deck boards spread iRe a wing | 5 singl-wing Wwoay Reversible mult-wing_| Reversible pallet having Boise deck boars spread likes | vowny wing (2) Dimensions of the fat pallets ‘The pallt dimensions differ from one country to another, and the standard dimensions tare decided by each country, respectively In Japan, the pallet dimensions are regulated by JIS, Z-060$, 0601, 0605 and 0606. ‘Tho 1.100 x1 (2) 100 me pallets ar called T21 type and are used as the standard for the Intermodal Paileization, Comparison of the Main Pallet Dimensions Regulated by the 180, JIS and Other Countsioe (Unit! ma) 1100800 sepan 1100-900 epan 1,100,100 | 11001 100 Japan (FH fe), South Kore, Taiwan, ASEAN counties 1100-1300, Japan, Eusopean Chemical Industy Association 100-1400 Japan 12005800 [1200-800 Europe (FUR pales), Japan 1.200%1,000 [1,200,000 Europe (VMF pallets), Japan 1,067%1,067 Now America 11401140 180 international transportation container series 121951016 For Norh America and other countries using the inch system 6(3)_Types ofthe pallets by material ‘Woolen pals |Curenly, woode alles are the most widely wed spe othe word but Japan asec sulfeing fom sborage of wood and unstable wood pcs Year afer S$} ‘year Their merits inlude tha ther prices are generally Tow, that comparatively Tighe causes no slippage of load goo and ht the can be easy ie. Pasi pallas | Rex he demand fr plac pales estes incesing aan alma 0 won ples The can be el colored, Jona damage lode goods andre BD | erriseeineecnt Thy ab ey tnd nc pewelgh Therefore they haves high iy vale depending on ir ‘ppliatons. With more manures pods then, he deslopmen no he most advanced nthe wal crates | et pats have higher sng, daily a shaping Nein wooden and other pe of pales. However try ere more expensive, generally heave, ot ean pair and stipe. Aluminum pales | Consion sistant aluminum alloy pallets ae light-weight and highly workable, but are too expensive. Paper alls | Various hrow-away ope corrugated eardboard pallets have been desianed, They tne inexpensive, but ave low suena, ‘Sheatpalles | These are shet-chaed pallets mainly used for push pl Felis Thay are made ot paper, ineloding fiber boar, or resin. They have been developed and difased Inthe US. and ae used in Jopan manly for ariulural products and exports (main types | 3 PES (main Insertion Fat wooden ples | "P=" ("i806 pes arsed in| peo, | ion Pome US 20615) reno [econ |12t” | er Fntpatcstir [Reverie wo-way 310044) 1.100 imemodsl [typeset wooden [MICO 1I°| | insertion pare ansponaton (1S [ples, type ot 10mm Zos0i:2001) | past palles) Bape escelpalis [BRECON | OT Insertion po 0 Farsectpaties [297 BPS | cacrca with | arpa. 1, | Mstion pos G18 2 065:1989) | frewooden | 1Smadze ee pallets) rtatplasicpats [S90 (Stypestess|/IEMECEP® | oiypes. 025, | insertion port atplcmes lime wodce [Meanie | 050751, | shouldnt es pales) wenden ales) | and 1.51 | hans mm he porentesind deseipon in he Type columns aS manor Tor your afomnation, a(4) Structure of the fat pallets Deck board bard-shaped component constiuting the tp and bottom decks Those at both ends of the pallet re called edge boards Beam Refers toa component joining and supporting the deck boards over te ful length o constitute the iseron pot. Tnseton por ‘Refers tothe opening of he pallet, where the forks wo be inserted Length, width and | The length dimension ofthe beam or beam boats called the pallet. bight length andthe dimension in the perpendicular ection otis called the pale width. Als, te dimension fom th around contact sufi 0 Teadng surface or upper sustr is aled the pallet eight. (5) Rental pallets If all the required pallets are purchased for a warehouse where the handled cargo volume fluctuates greatly, a large amount of them may be left unused during a low season, wasting money. In a high season, ete. when a large number of pallets are needed, accordingly, it is possible to procure the necessary number of pallets during the necessary period by utilizing rental pallets 1m Japan, thore are two specialized rental pellet companies which have @ nationwide network of sales offices and depots. Both of them rent pallet supporters, nestainers, roll boxes, and collapsible containers as woll as pallets. Normally, a rental fois set por pallet por day. I is important to take are not to lose these pallets, always Keep track of their utilization status and return tho empty ‘unused pallets without delay to save on costs. 28Coffee break «= International standards forthe phytosanitary measures for the pallets for limportexport ‘The pallets for importlexport have to be made of wood properly processed according to the standards of each country: Currently, most countries have adopted the international standards No. 15 (SPM No. 15) for the phytosanitary measures publishod by the United Nations WTO, to use heat-treated materials or fumigated ‘The wooden pallets neod to bear the IPPC marking. The IPPC marking is made with a stamp to indicate a county name, registered packaging material produeer number, abbreviation for the treatment method, and IPPC symbol. The marking must be stamped in colors other than red and orange, at least in two oF more easily visible facing areas of the package. Once this marking is made, the said wooden packing material may be repeatedly used for import and export. (Example in Japan) [Registration of export wooden packaging material producer] Ministry of Agriculture, Frosty and Fishory, Plant Protection Station (Our registration number: 001088 JP-50010882. Stacking the palletized cargo A. Directetacking ‘When directly stacing the palltized cargo, its necessary to check whether or not the cargo in lower pilos is damaged bs the weight loaded on it, and aleo whether or not itis stacked in a stable manner. In addition, even if stacking ofthe palletized cargo is possible in terms of strength, ‘adjust the number of stackod pallts as not to exceed the floor oad limit. It is alo important to check whether or not the pallets used are free from probloms that make stacking dificult, such as being damaged, stained, wet oF ofthe singlesdeck type. 8. Types and selection of storage equipment ‘The following describes the main equipment used for safe and eficient storage ofthe palletized cargo. (1) Nostainers [estainers are portable steel pallets developed in the US, which has rack function ‘The following doseribos their merits and demerits Just like other storage equipment, nestainers are stackable, greatly improves housing ‘efficiency. Being highly carthquakeresistant in the safety aspect, nostainors ‘themselves have not often tumbled in the past earthquakes. (Some of the paletzed ‘argo placed inside them have flown out.) Stacking operations can be conducted easily tnd speedily forts one-point alignment on the rail, being effective in terms of eafety as well Itean be also loaded with housed goods inside. In addition, it des not need tobe assembled and so it saves maintenance expenses. As for the demerits, because the bottom of the nestsiners is coarse netshaped, a bottom board or additional pallet is required to store small goods. Also, when working with wooden pallets or PP pallets, toro stages of operations are required mich as stacking the nostainers and bringing in/out the pallets, Compared with ather storage equipment, the nestainer is superior in earthquake resistance, durability, processing capabilities (peed, degree of 30operational difficultics) and maintenance-free design. The most important feature is that each nestainer is an independent 3'dimensional pallet reck and can be directly ‘moved with lit, allowing for an easy Inyout change, (2) Pallet supporters Pallet supporters are one of the storage equipment for loading pallets. I is used by ‘omnecting pipes tothe pallet. Being able to be disassembled to pipes and Stings tis sfficiont for truck transportation. On the other hand, it takes time to assemble and because pallets are directly placed on the crossed pipes, they are inferior to nestainers instability (3) Patt ks (heavy racks) Pallet rackes ate designed for the forklift to bring in/out goods from the side. Since the Tork is inserted at a right angle, i is neceaeary to secure a wide operation space (or an ssl) between the racks. On the other hand, this rack is suitable for storage of cango such as firstin first out, low-volume high-mix and lot numberspecified, because a a(A) Drive-in racks Driverin racks redesigned forthe forklifts to enter the rack lengthwise to bring goods in/out directly. It has a merit of saving the area forthe forklift sisl. On theather hand, totake out a farside pallet, it is necessary to take out all the near-side pallet, wasting time and labor in terms of materials handling ‘This rack is efficiont for storing a large amount of an identical itom, but not suitable for storing cargo such as firwin Grstout, low-volume high-mix and lot ‘pumber specified Inthe case of ahigh-rise rack, itis fc to operate the forklift unles its operator is highly skied (5) Flow racks Flow racks are designed for the pallets to flow to one side with slopes and rors Tis suitable forthe storage of cargo which has tobe brought out on a frstin first-out basis, because they are stacked and taken out on the opposite sides, 32(6) Mobite racks Mobile racks aro designed for regular pallet racks to move sideways electrically of manually to sccure working sisles flexibly, Storage efficiency is enhanced by climinating stationary aisles for materials handling Compared with other racks, this rac is costly. To introduce this, itis necessary to fully consider its cost performance. systems ‘An automoted storage systom is available as equipment requiring a higher investment Goods are automatically brought infout from a predetermined shelf in pallet unit at high speed by automatically activating a stacker erane. Efficiency is enhanced in both storage and materials handling, bt it is necessary to take proper measures to respond to blackout, maintonance and the Fire Service Act. Tha facility i usually introduced exclusively for specific eustomers because only fixed-sze plots can bo used 3As mentioned above, itis important to utilize various types of racks to enhanc storage tfficioncy, but there ie a common demerit across all of them? each requires installation ‘work and cannot be easily moved or removed. ‘To the contrary, there are rental companies for the nestainers and pallet supporters Since they are easily installable, they ean be utilized as nocossary, For the cargo whose handling volume varies gretly from one season to another oF ‘whose storage mode fluctuates greats, itis recommended to avoid installation of large-scale stationary racks. 3. Storage of non-palletized cargo: [A. Case goods and piece goods ‘To store goods by case o pce, itis necessary to consider storage equipment separataly. (1) Light-weight and medium-weight racks ‘These storage racks are designed for manual bringing inlout of goods and are mainly used for storage and picking by directly loading small goods and ease goods. “(2) Flowsthrough racks ‘These racks are sloped to allow goods to flow from where they are replenished to the sipping dock, Its mainly wsed for first-in first-out eatton cargo. When loading ‘When picking(3) Mobile Racks ‘These are regular pallet racks designed to move clectrially or manually, so that working aislos are flexibly eecured. The loading factor is enhanced by removing fixed aisles for materials handling Compared with other racks, this rack is costly. To introduce, it is necessary to fully consider its cost performance. (4) carrous ‘This rack i designed to enhance storage efficiency by removing aisles inside the rack Allowing goods to be brought infout at a fxod positon, i is suitable for picking in a ‘narrow space and storing fine goods (Riot ocownaistpina deve) Wioreion| 1%B. Selection of storage equipment (cost-benefit performance) ‘When introducing storage equipment, it is necessary to understand the detailed contract rate and operation volume in advance, and carefully consider whether its introduction enhances storage efficiency and operation eficency to increase revenues from storage and materials handling. Hven revenues ean be inereased, it is also necessary to conser ift makes up for the introduction and maintenance expenses of the storage equipment. Incase various racks aro introduced thei installation and change would be costly, and ‘once they are installed, it is dificult to change their layout, possibly lowering ‘operation efficiency. In the case of operations which require frequent layout changes, rack introduction should forgo. In addition, the introduction of mobile racks should be avoided unless stornge space is enormously insufficient ina small warehouse The following table summarizes general introduction expenses and effects for your information. As mentioned above, however, note that they differ depending on the actual operational condition, contract rate, contract period, type and scale of storage equipment, and cost, Higherstorage | Renabe, eatily movable ffceney ‘enable easily movable ‘Movable on thir own Costly instalation and elocation - ‘Costly instalation, relocation and maintenance Higher strage and_| Costly installation and elosaion operation efficiency Higher operation | Cosy installation relocation and frequency sinenance “Expense) Low: One unt parshassble wt several tens of owsand yn. Medium: Purchase cost of several hundreds of thousand yen + installation cost. High: Parease cos of several milion yen » instal ” (Consideration of cost performance when the light-/mediumweight rack is introduced (Specifications) Dimensions! 1,800 (W) x 450 (D) x 1,800 (H) mm, No. of shelves: Vertically 4, Withstand load: 150 kg/shelf, Others: Boltless When this rack is used, stacking is not allowed beceuse of fragile packaging. If 40renrquare carton eases are stored, they can be loaded on four shelves with four ‘aes on each of them, allowing extra londing of 16 4 = 12 eases” with the bottom shelf amount subtracted, [Now caulateby month, + Improvement effect for storage efficiency = No, of extra loadable cases compared ‘with borizontal storage (a) a= 12008 3 terms worth = 36S ‘+ Improvement effect for materials handling = Reduced picking time compared with, horizontal storage 0) ‘3 minutes (potential effect time) x 20 days (monthly working days) = 1 hour ‘+ Improvement effect for accuracy = Improvement effet of accuracy compared with horizontal storage () ‘Monthly depreciation of introduction expenses (purchase cost + maintenance cost) oF Tease expenses (@) * 16,000 (special purchase price)» 86 (3-year depreciation) = W44timonth Effet calelation formu (ax nit stomge charge +b x unit rice of reduced ime) = * The storage charge is contracted at ¥15. The reduced time is set based on the unit price per one working hous feet amount foreach rack = (6 eases x ¥15 + 1 hour x W800) - ¥444 ‘¥806/month'unit Suppose 100 units are used, tho effet amount is ¥898 x 100 units = ¥89,600month, {In addition, there isa potential eect (cin the quality aspect, which is not numerically represonted in terms of accuracy improvement. The effet ean be also assesed from the creation of storage space, 38"Coffee break Fs ie of introducing the storage equipment > ‘The folowing describes the cas oflowered effcioncy both storage and materials handling ‘sa rosut of introducing the storage by prioritizing storage elcieney. Particulars, when starting anew operation ina newly built warehouse, i-is necessary to fully consider the ‘ype, installation site and space ofthe storage equipment, and son. (Caso of the nowly built overseas warehouse) Narrow racks were installed in the warehouse almost across the board by inhibiting tho aisle epace as much as possible, but the materalschanaling space was insufficient, rosulting in confusion of receivinglshipping operstions and sorting operations, rmorwover, insufficiont storage space of large cargo which cannot be stored in the storage rack a rack utilization rate remains at approximately 10%) ‘To prevent the above-mentioned failure, it ie necessary to secure enough materialshandling space required for receivinglshipping operations and to fully ‘consider the shape of stored cargo to introduce the storage incites, In order to secure the storage space itis also necessary to narrow the aisle space for picking as much as possible. However, when introducing the narrow racks, ete, itis ‘avential to examine the shape and quantity of the stored cargo. 2”C. Flexible container bags Flexible container bags are bag'shaped packages designed to store and transport powder and particulate cargoes. They are also abbreviated as Fle-Con, Container baeg ‘or Flecon bags. They are divided in two types by applications, round and one-way use, Generally, they consist ofa sheet and belt which are woven with strong chemical fer and can be filled with approximately 1 ton of Reavy substance on average. The long loop part af the strong suspension belt supporting the entire hog is attached to the top ‘of tho bag to facilitate te lifting hy a forklift or crane. An objct is enclosed into the bag ‘through the top opening which can be closed by ite gusset. The bottom of the bag is designed to open and close depending on the type, s0 that the contents will be discharged once iti open in the suspended state. Because the bags themselves are light-weight, easy to fol and inexpensive: they are used ina wide range of fields. Although their stacking is based on the effective height and flor load of the warehouse ‘and operation effcioney, they are normally stacked in $ ta 6 layers. Specifically inthe ease of a Slayer stacking: ‘To stack the 1*-layer bags, place them on the pallets and arrange them tightly without gaps using a forklit “Tosuack he 2% and layer bags, mount an attachment tothe farks ofthe forklit and sap ther 10 sack. << Precautions for stacking > ‘+ ‘There are two stacking methods: “pallet storage," which paces the pallet for each stacking layer to stabilize the center of gravity, and “direct loading.” which places the pallets only forthe layer bags and stacks the 2“layer bags onward drcctly In thecase ofa long-peried storage, use direct loading to save the numberof pallets sae, + When flexible container bags get distorted, lif them using a forklift and adjust the shape before stacking, beeause they may tilt or collapse ‘+ Stack the bags in order'0 that their numbers can be checked without climbing on them. + Before stacking, stamp the top of the flexible container bags into the shape of a mortar to enbsance stability + Stack the toprlayer of flexible container bags with « slightly inwan the edge to prevent its load to collapse. lant from Note that toprlayer slant by direct loading and stacking extended over the flexible ‘container bags (pyramid loading) may result in a stack collapse when a strong earthquake occurs.<< Precautions for forklift operations > Keep the body horizontal and do not apply strong shocks such as fast and furious Liking or lowering Do not perform one-sided lifting, slanted iting or horizontal pulling, When moving fexible container bags, lift them high enough so as not to cause {fictions at the bottom, In the case of moving the bags for along distance, they should be carried on pallets 4. Long goods For long goods such as construction materials, if many kinds of items are placed flatly in no particular order, they do not only require a wide space, but they also obstruct inventory management and materials handling operations, such as receiving and shipping. Accordingls, use the storage equipment shown below and place the goods vertically or horizontally in order, thereby reducing the required space and allowing dfficiont materials handling operations x ~| Upright support rack Racks for long-goods Heavy-duty bar rack E, Bulk cargo Bulk fodstuff such as wheat, barley and soy beans are generally stored in silos Fertilizers such as wes, lime and phosphate rock, and industrial raw materials such as clinker are, however, stored in rogular warchouses as well. When this is done, a retaining walls set up and cargo is stacked using a bulldozer or shovel ear. They may bb covered with a tarpaulin in order to provent seattering4. Floor strength, wall strength and effective height A. Determining the loor strength An applicable Japenese law requires the oor strength of warehouses tobe 3,600 Nim ‘or more in terms of loading capacity Because the lor strength is ealeulated from the strength ofthe flor surface, beans ‘and cokumns, the strength ofthese directly inerease the floor strength, << The floor strength required for warehouses > At the minimum strength of 8,900 Nim? = 400 Ign? in this rogulatory range, only Tight cargo can be loaded, Suppose cargo is loaded with TH1 pallets: Cargo moro than (1.1 x1.1 meters) x 400 kg = 484 ky cannot be loaded, When loading 5 stacks of 15-kg ease cargo in 6 layers (= 30 cases), their weight is 450 kg. Ifthe weight ofthe pallet is added, the total weight hoomes approximately 460 kg, allowing only one pallet to be loaded. Accordingly, warehouses for handling many kinds of items are generally designed to Ihave the strength of 1,200 to 2,000 kg/m? Whon storing heavy cargo for a long period, it is necessary to inerease the floor strongth higher than usual, For instances ‘When loading 6 stacks of 30"kg baggod cargo in 7 layers (42 bags) ona 1.41.1 pallet, their weight is 1,260 kg, and when these pallets are stacked in 4 layers, the total weight is 1,260 x 4= 5,040 kx. In this case the equted lor sength 5,080 ~ 184 (1.41 x 1.1)~3.272 kp Ifthe load on the floor exceeds the floor strength, even the 1-story floor may be partly ‘dented, which affects the foundation ofthe building. Also the 2%'story or higher loors ‘ill havo highor risks of collapsing. Accordingly i is important to figure out the floor load from leaded cargo and stacking conditions and never exceed the flor strength. Also, lopsided stacking should be avoided, such as concentrated or high stacking in specific places aBB. Strength ofthe framework and outor walls ofthe warehouse, Jn Japan, the warehouse standards have been legally stipulated, and the strength of the framework, outer walls and floors las heen set by announcements regarding the vogistration standards, te ‘The following describes the Japanese legal standards for your reference. For now ‘warehouse constructions or warehouse tenancy, make sure to confirm the regulations ‘and standards in each country. (1) Warehouses approved for the standard strength ‘The following lists the warehou proved for strength. 4, Following warehouses conformed tothe Bullding Standards Act “Stool ramed reinforeed conerote construction,” “reinforced concrete construction, “einforeod concrete block construction,” “brick construction” “stone construction.” “conerete block consteuction” and “other masonry structures »b, Warehouses with steel construction or wooden frameworks Warchouses applicable tothe fallowing ‘+ Warehouses with wood sheathing or inner walls (with specification standards) and “furring strips” Warehouses with precast concrote hoards, ec. + Warehouses with precast concrete boards, autoclaved light-weight concrete board, bor outer walls made of extruded cement panols or those made of other panel standards). 4, Warehouses under the standards of 3" to ‘+ Warehouses which inspections, conducted by manufacturers, private architect's office or others, prove that auch frameworks, outer wale orlaths are strong enough to withstand a load of 2,500 Nin? or more. Even in the case of the abovementioned warehouses, when the outer wall h ‘window or other opening sections and if ts width and height are 1 m or more, they must be reinforced with sufficient strength(2) Measures free from toad collapse risks Even if the warehouse does not fall under any eategory in “s ‘unnecessary to mect the standard by taking a “measure free from load collapse visks. or warchousee whose walls have the strength of 2.500 Nim* or leas it necessary to tac congo with an interval equivalent tothe height ofthe “stack’, i order to prevent ‘direct impact of load collapse tothe wall or take a measure to prevent load collapse with racks, ete shove, it becomes +#When rackes, et. ara not used ‘#When race, ete a 28 used 45. Determination ofthe effective height "To improve storage efficioney in warehouse, itis necessary to actively promote their 8-dimensional utilization, Ivis also necessary to confirm the limit for direct stacking of pallets without usage of storage equipment such as racks, ete (Example) When using & 160-may high TH pallet to sacl up ¢o 1,250 mm, 1,280 + 180 1,400 mm When they are stacked in 4 layers the total height is 5,600 min. | 800mm operation space room for the forklift, ete. is added to this height, the ‘oquired floor height willbe 5,900 mm, Since there are beams and ther electri wiring, lighting devices, etc. near the beams under the ceiling, itis necossary to determine the number of oaded eargo and londing height so as not to obstruct those articles, When using racks to store pallets loaded with cargo, consider loading the eargo on a pallet up to the full height with slight room spared for the vertical dimension ofthe rack 6Section 3. Preventive Measures for Load Collapse 1. Palletized cargo ‘The following preventive measures are available, but itis important to choose a ‘measure in consideration of the shape of cargo, packaging condition and cost performance. ‘The following table summarizes the preventive methods, Te sapped portion Easy tapping and. [Diticalt ora hardly sips, but the funstepping. and |and collect and has Inonsvapped layer tends | economical by [ask alos. to collapse. repesteduse._|Nevesaryto select estterals and [Environmentally the band acording eauipmeny {tient ante |tosbesizeotthe Paperstring band, | = stetch films which ond elspropyene band. produce waste every polyester band see! timeitisused. | Unsuitable fer strip, polyetiyene rope, bagged earg and rubberband slippery camed | ego. 2 [Veni Nmping by vertical strapping viteaion is pevente, bt the cargo may come Z|) lout tom the gape Be between the bands if only fe bends wed Vulnerable to hrzomal | & ibaons. (Mates nd equipment) Ste as sown no. ear | aaa Se] foe = [Same as shown in No.1 Low a[Comerpadd] Effective for verial ihe somerpad | The paper comer ed itatons, bathe cago | |materas are” | pads are not Tovizntt_ | [ray come out fom the | [recyclable dpe! |reusabe (For strapping | |gapsbetweentheandsit| Jews canbe reduced. one-way ws) = henumber a cassis too many Horizontally moistened the resistant, but ot : svength maybe renonbletostosis | E lowered & | otaeriats and z lesuipmen Same bands as shown in No.1, 2nd 3. Paper ier shin, wooden and plastic corer pads arava, erica and torzonal | | Apply aluing | When the amount i vibration-esisan, and (9 | Festorble oan impact. igud thetop of |few, manual the corgied | application of gue 3 Sedo sendy Sack anon de yrovotied —— fanimremeoe folipe fn |dcn nthe mat | [More veonssiant | |Site [anon wl Aba eee toe installed in a there isa problem of | eingmaod Event | g eerie pang tena o [Bsceravrenoes, | 8 [ricco [maser — a | application of glue, | glue does not come Spare eta, which is off) in many cases. cra ead ale Ne-teon— [Waneater we Frevetanefecishios | |petenans or fine olue snd [Sevens era Haye ast Patetcedergn te | iano gus, [Sips cn tah Tio ovrsanac] _ |Sommeen nd. wnat aoen [piace 3 lier ed Caen | espe Polen finn sch peck chins 4s5 Fe nd alae Thy ware? Teal ear frecnioefeisnigs | fadduprati [swings foie rewat ered Not potetned cays Cnanizatin of eo emgo [Emcee swing | [erttrot tr [who conts ecemugeinsig sek | leorgned [Salt be Pesagingot Sarteaboxe, fie Fregutrshapedcao | |Traspenand —|lntocaseofusigs repose adored | cts sn xing mee fBerater Shinn | |atoneyouo [eis mio the fseitaroraee | Slarecyscemd late ottepae fmmpecingcwiois | lenient ut Comat be igs een ficn tes fii tame [Soeate pees | —latfed be cas flange ty nd ott ant ‘Noster fees ge wee eases) rovatng tet (trical | Heat shrinkable film because the cargo is [evetim pipette | | sale within in, eqn cha ome Sa) 9 [inerionot| [neve wane ones | [Comput wit [Tian ne feisty | —ererening ozone | semen ny lave mais et sires faving pape, [andere bo of rpocite ltecomsed g|revencd tom [ened boxes 4 [Snead tig [Sey eee 2 Japon pula [oly maha ates |putiy nas oni exch |cntae preom sce 10 [Boxtane | [lip etecve fr | [Nomedio omc [Saking unt evening oats | | scng mab ftioed dcop of med ie coms et lean ot 3 shear ant, Jirregularly-shaped esuenEthier pening | [Convention |Nosarking of esse revenge [pte deny o [imitstaetca,| [of untae 2B lenmitemstea ene. 12 [zonal | [Lamps otcicd | Ea robcnand [Reale fetng | lempoantmereetocie | faetttd ” |aiteatio fSeterzans sragping| lesen ty [etal and fmcouesteh suite | —|rpenadise (lout, wich anata Enmexay fest oe io B trenty nite |Ressary tose soc fim wich [tnd cc Frederwase, [esr fled rey neu 13 [Pasco | [Capaticafprevenigs | [Acorn | Gondomay mrte eee | [Stan feud bk | clo om Jey en eo ]| it ovine. |oecae ye & Combined with oat |_| any wilt felony ose colapepevnive |g |snencb aed og [tana ats ot] | eof et stows tte | 3 jms otar [Rat wetctvetor_|* [raion ex) [rong damage oot | | Penalmlting ota enn inane ere wos so ava (Wate) © High effect © Medium eet, A Low effeo Inthe cas of plltzing ina “lack patter” o slippery canned cargo such as iter square cans, the above-mentioned methods, and are na sucion It's recommended to adopt method 7 ot Sasmuch as posible soShrink wrapping machine 2. Rackstored cargo ‘To store cargo in racks, fll preventive measures suitable for the eargo should be taken, in consideration of preventive mensures against the turnover of racks themselves. ‘A. Rack and shelf fall preventive measures (1) Fixing racks to the building (fixing tothe floor or columnfbeam) Fixing to the floor with anchors (elect the diameter and length of the anchors in consideration ofthe weight ofthe load)(2) Fixing racks toa beam/column with a wire wl (Fix the building to stabilize) (8) Arranging racks in multiple rows to bind them together Bind oO x Lay out racks in multiple rows. 2(4) Connecting the top ofthe racks ‘The racks are stabilized ((5) Increasing the earthquake-resistant strength of the rack Design the rac tothe earthquake stant strength Use racks conforming to the “JIS20620 Industrial Racks.” Since the JIS does not assume an earthquake with a seismic strength 6 or more, however, itis preferable to design the racks inorder for it tobe capable of enduring lange'scale earthquakes, B. Measures to prevent f (1) Fallproventive bars fom the rack:(2) Fallpreventive wire netting (3) Slip provention By enlarging the contact area betwen the loading surface of th rack and the bottom surface of the pallet, the fiction coefficient ia increased to preduce an antislipeffact preventing cargo from falling. (4) Slide type fal prevention Staves and studs can be freely arranged within the frame ofa sliding door to handle diferent types of cargo. ‘This is optional for stacked cargo such as eases, 18liter square cans, pails, et. ‘The unreachable sliding door ofthe 2 layar or higher can be openedielosd from below, proventing the fall ofthe earg,(5) Others Steel plates are attached tothe centar ofthe shel to prevent the pallet from falling.Section 4. Location Management 11, What is location management? Location management means to sot a “storage place indication address in the ‘warehouse = location,” to link the eargo with the storage locations to manage them. To allow low-cost operation in the warehouse, this should be designed for anyone to easily ‘operate, Location management clarifies what is stored where, allowing efficient inventory management and materials/handling. Divide tho areas into fixed size foreach Moor (story) of the warehouse, each area of the Moor, and each zone of the area, and allocate Tocation numbers to them, Specifically, manas ‘warehouse as guides. Install signboards and panels so thatthe set Ieeation numbers ean be understood by anyone. tho locations by sections using the beams and columns in the ‘Management of pallet racks, mediumightweight racks or respective frontages may ‘be required for more detailed management levels. ‘The actual degree of location management differs depending on the storage mothod, shipping mode type of packaging, minimum unit of shipping), and so on. ‘hange 2ne indications 01, (002,003 and 008 56 aA a os “ [ae] [ee] . [ase | [ae] ° | | " ‘The caso above shows that the copier machines are located at AA-OL, AA‘O2 and AAO3, ‘and copier paper at AB-01, AB-02 and AB-03, respectively so2. Setting the location number A. Notes for setting the location number ‘When setting the location number, it is necessary to note the following points, Operational requirements for consideration + Whether it is easly understandable for workers + Take account of picking path (whether a tnicursal flow line is drawn, without Dbeckward movement) ‘+ Location numbor structure in the WMS (upto the dgite the location number can be retsined) Restrictions on hardware + Building and floor structure ‘+ Materials handling equipment to uso (type of storage equipment, with or without transport equipmend and layout ‘+ Response to future expansion (expansion of storage and operation area: addition of storage equipment) and B. Location numt structure In many cases, there are restrictions on the number of settable digits forthe location numbers and the units printable to forms, depending on the WMS used. The following describes the case of the WMS (REWARDS) wtlized in Nippon Express Group. In the case of REWARDS, the location number can be sot in full 10 digits for 4 layers First, consider which level the location number shouldbe set and managed to Consider the management level according tothe storage method, shipping mode (type ofpackaging, minimum unit of shipping), and so on. ‘When placing items tobe shipped by piccos onthe lightweight rack, it is necessary to set not ony the rack shelf number, but the frontage number forthe 4 layer ifthe layer thas detailed frontages, Tin this case, it is necessary to consider an indication method within 10 digits, depending on how the location and frontage are designed, such as indicating the frontage at the 4 layer, rack shelf number at the 3° layer, and aisle number or a combination ofthe rack shelf number and permutation. xX x EX XE Thayer Pye F¥layer layer +1 layer (2 digits: Area (zone) + ae layer (3 digits): Pall rack, sisle number between the medium-fightweight, racks or rack number +54 laver (8 digits Pallet rack, permutation ftom the aisle entrance between the ‘mediumightwoight racks + ai layer 2 digits) Shelf number or frontage 58Reference) Picking ist and locaton numbers Generally, @ picking ist which is output from the WMS has the location numbors printed in ascending order. To shorten the picking flow line to enhance operation ficiency, tis important to set the location numbers in advance, so that the lw line will be “unieursal.” ©. Setting method < Case of setting the location number > — 5 — 5) 9‘Set the location numbers in a new warehouse. [ Setting conditions ] + The entire warchouse is divided into 3 sections. Use one of them, Section A. ‘+ With the main aisle in the confer of the section, manage low-volume high-mix items on the right and let using the free location metho. ‘+ For the storage equipment, divide the medium-weight rack and reck shelves into three, and et the frontage + Various forms are output from the office with operational instructions. ‘+ Be sure to inspect the goods before shipping, and then, package and ship them, (1) Considering the stat point Since various operation forms are output from the office and the picking pusheart yard is lorated in font ofthe office, consider each operation start point, particulary picking, Using the office asa base point (2) Considering the finish point ‘Since goods inspection is required once picking is completed, an inspection table willbe ‘the finish point (3) Considering an operation flow ine If flow line is drawn unicursally between the operation start and finish points, it looks like the above red line. Allocate the leation numbers so that the goods will be picked in the sequence of tis low line. (4) Setting th location number Set the location number in 10 digits as mentioned above (XX-XXX-XXXI00, Because of the necessity of frontage management, itis necessary to set a frontage ‘number for the 4 layer, + ayer (2 digits) ren and aisle: At, A2, A8, 4,5, AB and AT ‘When drawing a U-shaped unicursal flow line through the aisles between the vacks, set numbers for the aisles. + 208 Layer (8 digits): Rack serial numbers 001 to 012 [Asif drawing a U-shaped flow Tine, set 001 to 006 and 007 to 012 foreach rack from the entrance of the main aisle. + layer (8 digits Rack shelf numbers 001 to 005, Since each rack has 5 shelves, set 001 to 005 sequentially for the bottom to top shelves. + 4% layor @2 digite Frontage 01 to 03 ‘Since 3 frontages are set for oach shelf, set 01 to 03 for them, starting from your Teft hand side<< Example of setting the location number > BE < Reference > ‘The rack number aloestion method differs depending on the warehouse layout and flow line design (use of materials-handling equipment, rack installation method, ete.) x. 1: Retuming te flow line othe 2.2: With an automatic carying ‘eal aisle machine and another isl locted dsp “inside he racks and exiting fom the ‘opposite side ofthe entrance (picking) (103) 1 8 1¢—_2 2 7 3 4 3 6 8 6 4 5 71 he 63. Types of location management ‘There are largely two types of location management operation methods: fixed location ‘and free lcation, A. Operation method by fixed location ‘+ Fix tem storage oeation numbers ‘+ When the goods overflow from the designated storage location, it is necessary to post another storage location. ‘+ This mothod isnot suitable if production lot management or system based firsin first-out operation is required 'B. Operation method by free location + Generally, items may be stored at any loration, ‘+ When shipping, receive instruction for the appropriate picking loextion from the system. nventory management by WMS is mandatory) ‘+ Since the entire warehouse is storage place, itis necessary to periodically review inventory arrangement. "The following method is also available for the enhancement of chipping operation ficiency, ©. Double transaction method + Divide the space into stocking and picking areas to manage inventory. + Itienecessary to replenish inventory from the stocking area to the picking area + It is necessary to introduce the WMS because delicate inventory management is required across 2 areas, ‘When adopting the fixed location method for the picking area, it is neceseary to consider how many days worth of shipping quantity should be stored inorder to decide ‘the sizeof the storage loeation, ‘Analyze the shipping results to decide how many days worth of shipping quantity is appropriate from an operational viewpoint. It is also necessary to consider the replenishment frequency and socurement of replenishment personnel because replenishment operations are always required every time the goods run out of stock, @<< Mechanism of double transition > [arenes D. Merits and demerits ‘The following table lists the merits and demerits of the thee types of location ‘peration methods from a viewpoint of operation efficiency. Fixed location Easy to understand the item storage plce ona one-tem ene-lcation bss, * One inventory inreases, the gods overflow rom the designated location, aking itnecessary to manage them separately. Decide operation ules and ensure the workers ‘understand them, * Sine the location is exclusively occupied even if thre sno inventory, the inventory filing rate may be lowered. Fre location Because oe item can be managed at multiple locaton, this method is operable according tothe storage lume, increasing the filing ate * The picking flow line becomes longer because teenie warehouse picking aes + Tis necessary to sum up atthe time of inventory stocktaking ue to muki-oestion storage evn inthe case ofthe same item, Double Shorter ow line and more eticient shipping operations because picking operation are completed inthe picking are. “= Mare replenishment othe picking area. + More operation management such replenishment timing and count, securement of personel4. Introduction of improvement efforts Rack indication and work responsibility indication’ Nippon Express Qing Px Warehouse (Company-owned warchouse) Location indication has been unified and chased on any floor and in any building Because the daily acope of work responsibilities (operations and places) are posted, ‘off-duty workers and personnel in charge of putting up an indication hoard are also notified for easy understanding, << Unified location indication > < Indication of workers in each area with photos > < Indication of responsible persons in each area >Thore are largely two types of picking methods, “total picking” and “single onder picking.” Operation efficiency differs depending on which method is used inline with a ‘workplace and order volume. In addition to manual picking, there are also picking operations utilizing the information equipment such as handy terminals, 1. Total picking In this method, goods are frst picked collectively per commodity. Then, they are Drought to the materials handling area and allocated for each shipping destination, ‘This method is called “total picking” because the goods are collectively picked, or ‘planting picking” beemuse they are allocated for each shipping destination. =) (= LH2. Single order picking In this method, goods are picked up per shipping destination or order sheet. ‘This method is called “onder picking” becatse goods are picked item by item for each ‘order sheet, oF “single picking” because the relevant goods are picked up kind by kind. (tests and demerite of each method) + Short moving distance because specific items are collectively picked. + Few errors because goods are picked up item by tem. "Total picking nay to find a missing item because ‘he total shipping quantity foreach item i known | + Short moving distance in the ‘ase of amall-vsroty/lotabipping 7 Bay to understand the alla exrors, ete. of individual pickers because each order is dane by a single picker. + Con proceed to the nest operation process (packaging or strbution processing) because Picking incompleted fr each order Single order picking = Tes necessary to sort the sods for ach customer after total picking, requiring sorting space and extra vworke + Cennot proceed to the ext operation proces| vunlese total picking and sorting ofall the items have| ‘boon completed,3. Comparison of both methods and selection criteria Spike | a | o [gacetctenan J<1> Timing of| 8 Hxsd time | deploying the pickers intensively ee be r= eeere tems Shoe ow Tine fer Wie wal icing % cee | © fis 5 “zt |e fe | = prea antl | ane] | ier agape meee a meow gure z awa 5 Meme <2 19 < 4> ae simply compared in ters ofthe length ofthe flow ins, and the flow line hardly changes for the single order picking method. (However, it iz pocessary to arvange the commodities to be pieked in ander of the ruck mimbers and proparo an erder sheet) ‘The above is a general comparison, and it is necessary to determine the most afficient method for each customer, depending on the area of the sorting space, number of ‘trranged pickers and time, skills ofeach picker ad 8008, Reference) Point for considering the picking method Picking T oe * Rolay pecking, mut-lking, oe i fy tam delvery company, vehicle, + Paral picking (assoting). te ‘Sori method fo ach destination Shale ping, mpeg, wang 2 Points *+ Diferences among the picking methods depending on the unit of shipping and the uni of inventory management + Effects atributable tothe location and shape ofthe warehouse, + Limitations on operations due tothe shipping deadline andthe numberof batches (received or aggregated data volume). + Restrictions due to the tm shape. 64. Specific operational procedure A. Unit of picking Tn addition to single order picking and total picking, thore is ano rmultipicking, which requires a single picker to simultaneously pice multiple orders oF orders of multiple stores. method called ‘The unit of picking should be decided by analyzing the details of operations and the Pikes ski. SE aa ote Ope + A,B,C and D in th figure above are individual orders. Multipicking doos not equive sorting, but total picking requires sorting for each store, ee B. Picking indication method ‘The picking mothod is indicated by picking lists, labels, handy terminals, digital Picking eystom, picking carts or vico. It is necessary to select a suitable method in consideration of cost performance. * S00 “Cole broak’ below forthe handy terminals and digital picking. Labels eample) 68Coffee break '* < When WMS is used for the warehouse management, handy terminals have been utilized for picking operations in many eases. With handy terminals, itis also possible to prevent picking errors and manage the progress of operations by scanning shipping order item number barcode, storage rack numbers and item number bar code, and inputting the number of picked items, < Introduction of digital picking > Digital picking indicates a picking location and quantity by blinking an indisation lamp through a control computer to assist picking. Compared with conventional picking dependent on the picking lists, order slips and skilled workers, productivity and accuracy of picking and sorting operations are enhanced dramatically at logistics ®CC. Examples ofthe picking methods (1) Relay picking In the case of circular picking method, which is generally adopted, tends with picking by a picker In relay picking on the other hand, once picking in a zane is completed, a picking box is «ent tothe next zone and multiple pickers pick goods forthe same shipping destination, ‘thereby shortening the pickers flow line. < Concept of lay picking > a oa E 5 \ range mae ‘ope [8 ne, STLSEe. SSctthe 702) Area classification ‘When the picking space is wide, there is another method. This method isto dive the picking area and picking is operated in each area for the same order of the shipping destination, and assemble them at the end As shown in the figure, the picker's flow line becomes longer in the assembling. Dividing the area shortens pickers flow line, but assembling i required ern)(3) Mutipicking ‘Multipicking is a picking method for single picker to simultaneously pick the goods for ‘multiple shipping destinations ‘Mainly using picking cart and linking »cllestion box to a shipping order, the goods are sorted fr each onder simultaneously while picking. ‘Because picking and sorting are conducted atthe same time, more sorting erars occur Tt fs alzo necessary to educate the workers and introduce an inspeetion proces < Concept of multipieking > SRrMtetee comrkaeaten comma suman conn cpaee A ea oo oo oop Buds Free lcaton or fied locaton L(4) introduction examples ‘The following describes the advanced picking method at Nippon Express (Netherlands) 1 Pick by voice (Picking system by voice guidance) A voice guided picking system has been adopted for carton picking. As indicated by the f the commodity, and as indicated by the voice, the pieker picks the quantity of the ‘commodity, pronounces to check the quantity, to complete the picking. Picking efficiency has been enhanced due to hands-free operations. ‘ic, «picker moves to a picking location, pronosces to check the JAN CODE. 1 Pick by light (Picking system by light indication) When shipping labels are printed and affixed to boxes, and an installed barcode reader scans the SSCC on the labels. Then, the picking quantity is digitally displayed and the lamp is turned on Pick tho commodity and pross tho lamp to tum it off. In this was, picking is quickly completed Ey1 Pack Line Systom (Weight measurement system) ‘Measure the actual weight of the case and compare with the weight value sent from the WMS. In the ease the difference is greater than a the inspection lane to inspect its contents, and if t is within the tolerance, itis sent to the sorting lane as specified by the WMS. stain val, the case is sent to "4| (epapter Storage Operations || To master the quality management and inventory | management methods of the stored cargo as the || basics of storage management. | ‘The basi function ofthe warehousing industry, especial storage operation, i {ohana over deposited eatgoaeits, ute notoay o comply wih nctons Decause of risks such as qualty detooratlon,contaminatondamage and | inveiory discrepancies. Its nacassary to lear the “qualy management methods ofthe stored cargot || suchas empeature and huni management, prevention of erage caused Dyrats, birds and pests, and preventive measures for fe, dust ana ocr, a5 wall a8 the Naventry management methods for preventing en Inventory ascrepancy. || This chaptar is intended to mastorthe basic storage management methods and Io offocvely make use of them nthe review of te current storage management and effots for improvementSection 1. Quality Control of Stored Cargo 1. Quality deterioration preventive measures by temperature and humidity control AA. Necessity of temperature and humidity control Various ango stone in the warehouse may suffer from product deterioration caused by decas, quality change, mold growth, et. or packaging or exterior defects due to the temperature and humidity in the warehouse Particularly, perishable fodstu such as fruits, vegetable, fsh and shellfish, and meats quickly deteriorate when stored at normal tomperatare nonder to prevent deterioration of cargo aceordinely, warehousing business operators need to store it in the optimal temperature zone for the cargo, from normal temperature, low temperature, chilled temperature, rofrigerated temperature and freezing temperature zones, For rice and perishable foodstuff, humidity control also Important for preventing mold, ete. and keeping a moisture value, weight, quality te Constant temperature and humidity may be Kept based on the contract with the(1) Temperature and humicty control with air conditioners ‘The cargo requiring sperific temperature and humidity control needs to be stored in the warehouse equippod with air conditioners, et. to take care ofits quality statua. To store new eargo, accordingly, it is necessary to confirm the specific cargo-handling ‘method with the customer, they exceed the facility or personnel capacity, they should not be easily scoepted ‘A warchouse provided with a function to keep a constant temperature is called & “constant‘temperature warohouse” and stores plenty of foodstuff, medicines, medical appliances, precision equipment, etc. Also, trunk rooms with constant temperature ‘and constant-humidity eapabiltes are used to store household goods Coffee break += Ordinary tomperatare > This refers to a standard temperature which indicates « mnstant temperature, ordinary temperature or ordinary temperature throughout the year. On the other hand, it may be applied as strict standards the general rulesof the & { Japanese pharmacopoeia set thatthe normal temperature for medicines te. should be 15 to 25°C. The Japenese Industrial Standards set that the “ordinary temperature” range is 20°C + 15°C (5 to 35°C) GIS 78708) this temperature range is applied as the $ normal temperature tothe standards, regulations, et. for most Japanese products and commodities such as industrial products, daily necessities, foodstuff, ete, Likewise, tormal humidity refars to a relative humidity range of 45 to 85%. Also, for the 1 foodstuff stored at the ordinary temperature, there may be individual indications auch as “their frchnoss date is set according to the ordinary temperature criteria of 15°C for winter and 25°C for summer” Algo, a ordinary temperature warehouse refers to § warehouse fre from temperature control by air conditioners, ete. (2) Temperature and humidity contal of warehouses without air conditioners, ee (orcinary-temperature warehouses) Even if warehouse is not equippod with air conditioners, ete. (rdinary‘temporature ‘warehouse, it should be installed thermos-hygrometers in the warehouse to measure ‘the highest tomporeture (particularly just after noon) and humidity during the daytime from a viewpoint of quality management of the stored cargo. When its internal temperature or humidity rapidly increases, take the following measures for “ventilation,” “air cireulation,” and “dehumidifietion’ to control the temperature and humid ‘Open the doors anu windows to replace the warchowse internal air with external air “Ventilation” n‘Run the fans to cireulate the warchouse internal ir .. “Air circulation” [Run the dehumidifiers to dohumidiy )ebumidification” 1B, Measurement of the temperature and humidity ‘To accurately measure the temperature and humidity, prepare optimal measuring instruments that ft the actual management conditions of the warehouse. Install them in their required numbers at the necessary spots in consideration of the temperature difference among the different spots in the warehouse. Inspect the measuring instruments being used by comparing the temperature and humidity ofa few of them toensure that they are functioning accurately. (1) Types of measuring Instruments 4, Digital measuring instruments ‘Many digital measuring instruments are commercially available, which display langesize numerical values on their sereens for easy viewing. There are many kinds of them priced approximately 1,000yen to 3,000yen. Some af them even alert you for sold and mites. b. Hygrothormograph ‘A hygrothermograph is @ measuring instrument which measures respective temperature and humidity. The measuring needle tips come into contact with and record on the surface of paper (recording paper coiled around a eyinder which rotates slowly at a constant rate, Proper care should be taken for this measuring instrument jn order not to run out ofthe vecording paper, ink and batteries. Annual accuracy checks may be required aa a rule according to tho customer's request forervor management for each instrument, ror check duo to aging, and so on«. Paychrometer (wet andl dry bulb thermometer) Based on the difference between the dry- and wet-bull temperatures (difference ‘between the dry and wet bulb), this measuring instrument is designed to obtain @ relative humidity according to the relative humidity calculation table provided on a peychrometer In this ease, the dry-bulb temperature isthe atmospheric temperature. ‘The disadvantage ofthis measuring instrument is thatthe difference of graduations ia checked visually, resulting in diferent readings depending on the viewing angle, A reading errr of even 1°C can result in a relative humidity difference of 10% or mone Temperature and humidity data recorders ‘There are recorders capable of saving tens of thousands of information points at constant time intorvals in the form of digital data. They are priced at over 10,000yen. Compared with the conventional hygrothermograph which recorda data on rotating recording paper, they allow you to understand data transitions on your PC sereen or ‘have a function to alarm you at a specified value, Analysis with analysis oftware ”©, Others In onder to enhance power-saving and rationalization of temperature and humidity measurement, remote monitoring systoms utilizing the Internet and warehouse inspection systems utilizing handy terminals have been developed. (2) instal jon spots Measuring instrument should be placed in atleast one spot, Suitable installation spots fare near the entrancelest of the warehouse, where itis exposed tothe outer air and deep inside the warehouse, or its comer areas surrounded by eargo, where the temperature tends to rise, Alo, it is necessary to periodically measure the ‘temperature atthe upper layer of the “stack” because the temprature may have riso * For constant-temperature stored cargo, temperature showld be measured in two spots, the lower and upper layer of the stack, based on the self'storage manual inthe case of government-controlled rice (8) Saving the record It is important to prepare a “daily inspection table,” ete. and continue to record rmeosurement results, Particularly, itis necessary to instruct the warehouse stall to implement this as a daily task, C. Humidity control measure Humidity control measures in storage management are particularly important in terms of quality management. That is, higher humidity may promote generation of ‘mold and insects and quality deterioration. It also inerenses tho risk of stack collapse ‘as 4 result of the package exterior of corrugated cardboard eases being weakened or dented due to moisture, ‘Major humidity control measures are as follows. + When the outer nir humidity is low open the doors and windows to ventilate + Run the dehumidifiers, + Run the blowers. (1) Relative humidity and absolute humidity Humidity refers tothe “eteam content in the six” ‘There are two typos of humidity: “relative umidit:” which indicates the moisture of the air (Gi) at @ certain temperature, and “absolute humidity which indicates the steam content () in the ar. “Therelatve humidity is calculated sfllows. Generally speaking, he humidity means the relative humidRelative humidity (4) ~ Steam content (gn) + Saturated water vapor (i?) 100 "The saturated steam refers to the maximum steam content contained in 1 "ofthe air aa certain temperature, (2) Saturated steam and dew condensation ‘The amount of saturated steam differs depending on the temperature. The air contains ‘more steam as the temperature becomes higher, and contains less steam as it becomes lover ‘When the air is cooled and the steam is saturated (100% relative humidits), the ‘temperatures called a “ew point temperature.” Ifthe air is further cooled, part of the ‘steam turns to water. This phenomenon is called “dew condensation." When the cargo ‘stored at low temperature is brought out af the warehouse, the air in contact with the cargo surface is cooled and generate water drops. This is the result of the dew condensation phenomenon. Particularly in the summer time when the warchouse internal temperature differs ‘greatly fom the external temperature, accordingly, itis important to prevent damage ‘caused by the dew condensation. Specific mensures include temperature difference «ontrol by moving the shipping cargo to an intermediate temperature zone in advance. 8Coffee break = & ‘Temperature change and dew condensation Reatsn between At Tempest and Stated Wate Vapor Aivenpener 0S 1S ued ean (nn) 496893 a ” @ in Dew cong conde awe wwe | we 1h) ty 0% | | sony 0 fl] YO | amy 0 Sem 238 Sem 1278 Seam 932 In Waers4e (Explanation) ‘Theaie at a temperature of 20" containing 12.7 g steam in I m* 4 Once the air temperature becomes 15°C, the steam will be saturated with the saturated water vapor of 12.7 at 15°C and start dew condensation. Here, 15°C isthe dew condensation tomperature ofthis ar ‘Once the air temperature drops to 10°C, this air can contain only 83 g of stsam. The Aiffrence of 3.4 g of steam is condensed into water. (The air volume is unchanged.) * Excerpted from Guide to Storage Management of Rice and Wheat (2005 version) 2D. Management of air conditioners air conditioners do not operate proper, the quality of stored eargo may deteriorate {due to the generation of mold and insects, which eould result in damage claims from Accordingly, maintenance of air conditioners is an important operstion of the ‘warehouse Generally, the approximate air-ooling capability of air conditioners depends on its horsepower, A horsepower of 10 ean cover an area of approximately 119 to 178 m ‘Since commercial warehouses are generally equipped with multiple ar conditioners it is important to check al of them. (1) Inspection of air coneitioners tis necessary to check whether an air conditioner iteolf maintains its intended Functions, ‘The following lists mejor inspection items. Whether or not the air conditioners filter is clogged. Whether or not the est temperature is kept. Whether or not the drain pan (water drop receptacle) is logged with dust, ete Whether or not there are abmormal sounds or vibrations Whether or not there is a eonsiderable change in power sage Whether or not the drain pan or duct is moldy mS, (2) Precautions for stacking ‘+ Ensure that the cargo ie not adjoined to air conditioners, duets or water suupplyidrain pipes. ‘+ Ensure thatthe cargo is not stacked high enough to block air conditioners. (3) Measures needed in the case of abnormality Lf air conditioners are left out of order, mold may generate as the temperature and humidity rise ‘To prevent this itis necessary to check air conditioners for any abnormalities when Ingpecting the inside of the warchouse nnd measuring the temperature and humidity in the moming and evening. Ifany abnormalities are found, ise important to repait ‘thom or arrange rental immediately It is also important to record the time noded for ‘the repair the temperature change in the meantime, ete. in detail. When it takes time to repair, ete, i ie necessary to obtain the customer's consent and move the cargo ‘nother warchouse.2. Anti-at, anti-insect and anti-bird measures ‘A. Measures for damage caused by rats (1) Necessity ofthe measures In today’s society, where aareness of fod safety has been increased, all cargo may be rotumed as having no commercial value, because of not only direct damage caused by being hitten by rats or insets in the warehouse but adhesion of slight excreta or insect ‘ges to packaging. Miscellaneous goods other than foodstuff may also be returned or subjected to damage claims if there isa trace of boing bitten by rate or a carcass found inside. Inthe worstease sconario, it may become credibility problems with the manufacturers, You are exempted from the responsibility according to warehout deposit contrac, but in the case precautions ee. are neglected, you will naturally have 1 compensate for the damage. (2) Antirat measures ‘Major factors that allow inhabitation of rats include availability of food, ast-uilding places, nest materials, and fre activity apace. Since availability of food is particularly a big factor for the inhabitation of rats, ‘management offoodstu in the warehouse is important. 4, Examples ofthe preventive measures |. Provention of thei intrusions ‘Once a sign of rata is found, any rat intrusion paths should be shut off immodiatoy. You should also repair any gaps ofthe doors or walls, any holes inthe well, tectonic ‘windows, broken parts of the building, ete, and apply an anti-rat brushes, anti-rat paste or wire net to the tectonic windows or crevices and attach mouse blocks to the entranceenit + Signs of rats (signs of inhabitation of rats in the warehouse, such as foes, footprints, paths, trace of bites, and smell of rats excreta or carcass) << Tools for intrusion prevention > ra A<< Mouse blocks > 1. Removal of food and cleaning It is sald that rats die ifthey do not eat for three days, and that they reproduce 0 to 100 babies a year. Accordingly, make sure that there is no feod or no nest building materials, o that they can not survive even if they intrude, Remove unnecessary substances (paper, waste corrugated cardboard, waste pallet, eta) left in the corners of tho warehouse to eliminate any hiding places (nests) for vats, Always clean the small annexes of the warehouse, resting pla stockyards, and s0 on. 1 for workers, (Clean or dispose of rice powder or opened returned foodstf. |i. Applying or spraying repetiont ‘To prevent cables, electri wies or pieces of facility equipment from being bitten by ‘ats it is effective to apply or spray repellent. iv, Notes for stacking Secure a path on the wall side through where workers can pass, Rats cannot be prevented ifgrains ar stored cloce tothe wall . Rats pest control methods In case the intrusion of rats cannot be prevented by taking the abovermentioned set sary to capture and exterminate them, |, Capturing and extermination of rats Capture and exterminate the rats, Adhesive mousetrapping cardboands (cardboard with bindlime), mousetrapping eages, ete. are used to capture them. Especially, adhesive mousetrapping cardboards are easy to handle and allow you to colloct and dispose of captured rats in a sanitary manner. 88‘The adhesive mousetrapping cardboards are useful not only for capturing the rats but fas materials to monitor the generation of stored product pests. Therefore it is Important to carefully observe them during patrols. Professonal-use adhesive mousetrapping cardboard 1. Use of drugs to exterminate rats Use drugs (toxic bait leat poisons) to exterminate rats, The rats would be dead by cating rat poisons (eat pest control agent). However, do not use this method when Sodstulf or beverages ae stored. «6 Extermination of parasitic mite on rats If vat carcasses or nests are left intact, parasitic mites (house dust mites: ‘lood-sucking) may spread throughout the warehouse. In the ease damage caused by ‘mites is found, look for rat nests or eareasses, romove if any is found and clean the spot, ‘and spray mite exterminating insecticide 1m the case the rat damage is serious, it should be assumed that there are many intrusions and moving areas, requiring a detailed survey: Since the survey requires expartic, it is rocommended to request professional extorminators to exterminate theB. Measures for damage caused by insects, (1) Necessity of the measures ‘The intrusion paths of insects include adhesion to stored cargo, moth intrusions into the warehouse, ct. In the case living insects, dead inseets or pupae are found in stored cargo, they will be returned or claimed for compensation. Even in the worstcase scenario, acordingly, utmost care should be taken to find them inside the warchouse land not to ship the cargo together with them. In the past, there was «ease which they had been found atthe delivery dest tion, resulting in a serious damage claim. (2) Types of pests Stored grain pests mainly feed on relatively low-moisture foodstuff such as grains, beans, dry noodles and confectioners. They are also called dry pests. (3) Anttinsest met evertive measures |. Tiaying up Refuses of grains seattered and accumulated on the warchouse floor, ete. tend to be a pest generation source. Tidving up isa basic and effective measure 4. Drying Higher moisture encourages the reproduction of posts, Stored cargo shouldbe dried to ‘an extont that it will nt be affected, by opening doors, turning on fans to circulate the air and running dehumidifiers. Low temperature Most pests become loss active in their growth and reproduction rate at the temperature of 20°C and they stop completely at 10°C. To prevent pests, according it is preferable to store cargo at low temperature b. Monitoring (dally inspections) ‘There are two monitoring methods: traps and visual cheek. |. Visual surveys. Conduct visual surveys along with daily warehouse management operations, a1. Trap surveys (pest capturing traps) Install traps at fixed points in order to accumulate continuous data on the types and ‘quantities ofapturod posts. Although the observation frequency difers depending on the life cycles and capturing conditions of the target pests, it is recommended to bsorve them monthly. |W. Contiemation surveys In light of the survey using traps, when inspecting the spots where peste were captured, iis necessary to survey by lowering the eye ines to where the peste actually are, such as maize weevils, which damage cargo from under the stack. In the case a hole made by a pest is found in the packaging during the survey it i necossary to check whether the hole was made from the inside or outside ofthe stack. [itis made from the outside, there may be generation source in tho poriphery, and if made from the inside, adjacent cargo may also have boon damaged, (4) Extermination (use of insecticide) ‘Furthermore, in the case the warehouse is infested with a lange numberof pests itis necessary to “fumigate” with a highly insecticidal gas in a fllledsed manner. This sst be done in complianes with the restrictions provided by the applicable laws and regulations "Coffee break = << Example of damage by insects > A Japanese logiticaconter had bean storing and distributing a largo amount of cargo of a doily necessities manufacturer to various wholesalers. When they disteibuted the cargo based on a delivery order as usual, they received a complaint that insects ad ‘been found on the exterior corrugated cardboard cases. "This complaint was passed from a wholesaler tothe manufacturer's main office, and to ‘our main office in Japan, resulting in the return of all the eargo. Adhesion of th Insects was attributable to an outbreak ofa large number of insets in the warehouse ‘The biggest problems i thatthe insects were not found at the time of storage, picking, shipping, lading, delivery and handover. Every person concerned should be aware that they handle daily necessities which require attention from a viewpoint of hygiene. 88C. Measures for damage caused by birds (1) Necessity of the measures Damage caused by birds associated with hygiene is mainly caused by droppings and rites parasitizing the birds. Damage from droppings includes contamination ofthe cargo and the workers in the ‘warehouse, and bad edor. Droppings also lead to secondary damage such as induction ‘and outbreak of pests, and the induction of rats, ot. Damage caused by mites includes mites deriving from birds such as northern fowl ‘mites, chicken mites and dermanyssus hirundinis. When the habitat density of mites Increases or their host (ied) dies, they may spread indoors and sting people, seeking ‘nother source of blood. This damage often occurs when a nest is built under the eaves ‘of the warehouse, ete (2) Antbird measures When taking ant-bird measures, it i important to basically hold off the birds before ‘they build their nest Firstly, aw clean the warehouse, remove rie powder, et. and never food the birds, Socondly, use repellent spray or gel type repellent, or hang eyespot balloons, CDs, bind-preventive tapes, ete. as 4 means to prevent birds from sitting or inhabiting the ‘warehouse. Inside the warehouse, spray a repellent on the resting places and nests of ‘he birds However, doves have a strong homing instinct and may die on the spo, inereasing the cutbreak risk of mites. In the places where it is difficult to drive them away, it is, necessary to install wines or bird nets to physically prevent them from intruding. Installation of wires or nets is dangerous because it is often required in high places, Tt {is recommended to outsource this task toa pesthharmfl animal exterminator. 9