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How does the warehouse work? The 4 basic stages with an overview.
1. Storage.
It is a comprehensive process that handles the warehouse management of a company. It starts with the demand analysis itself, through the generation of orders, to the receipt and storage of goods. The final step is the dispatch or receipt of goods by the customer.
Goods must be stored securely and their flow in the warehouse unimpeded.
Efficient storage requires the provision of:
✔ trained staff,
✔ the necessary storage space,
✔ specialised machinery and equipment,
✔ adapted equipment (shelving, picking tables, storage furniture, etc.),
✔ appropriate management system.
2. The storage process should be divided into 4 main stages.
Acceptance of goods.
As the name suggests, it involves bringing goods into the warehouse. It begins with an analysis of the documents and a check that the goods received completely correspond with them. At this point, an inspection of the physical condition of the transport is also carried out in order to detect any damage as early as possible. Once this has been verified, unloading takes place. This takes place in special reloading docks. From here, the goods are directed to the receiving area, where they are segregated, labelled appropriately and transferred to storage.
The proper functioning of this stage optimises operating costs and minimises the risk of delays that would affect further activities and the efficiency of the entire facility. Good organisation and communication between suppliers, transporters, distributors and the warehouse is key here. Early detection of any irregularities, even the smallest ones, will allow an immediate response and the prevention of delays.
Storage.
Delivered goods are placed in the storage area in an orderly manner and according to requirements (e.g. appropriate humidity or temperature). Good organisation at this stage has a significant impact on the operation of the entire warehouse.
The distribution of accepted goods in the warehouse can be based on one of the many methods used, the most common being:
✔ method of free storage spaces,
✔ method of permanent storage spaces,
✔ ABC method (the so-called stock rotation method).
Storage will not run smoothly without a warehouse management system (WMS). It oversees labelling and allows items to be located quickly. The WMS provides a real-time view of current stock levels, so goods can be replenished in advance and shortages and downtime in shipments do not occur.
Picking.
It is the retrieval of goods from storage areas in order to piece together the orders placed by customers. These activities are usually processed manually by employees, with the support of automation and mechanical equipment.
The picking consists of:
✔ collecting goods from the storage area,
✔ picking the order,
✔ to check the conformity of the picking with the order placed,
✔ secure and pack the goods so that they are delivered undamaged.
Issuing.
The final stage of the warehousing process, consisting mainly of the release of goods to the recipient.
This is done in a dedicated area where they are carried out:
✔ another verification of the goods to be issued – checking documentation, completeness and labelling (correct consignee details, delivery address, etc.),
✔ proper loading of goods, according to the route assigned to them and the means of transport chosen.
3. Optimisation of storage and flow in the warehouse.
To optimise the performance of the entire warehouse, each of the above-mentioned stages can be influenced.
Receipt and issue of goods.
Improving the operation of the unloading docks is of great importance. This is possible when the WMS efficiently schedules delivery and collection times, which in turn prevents queues.
Storage.
In the case of full utilisation of warehouse space, it can be a good solution to adapt storage methods as much as possible to the height of the building. High-bay racking with fitted pallet stacker cranes can help.
When it is possible, it is worth thinking about reducing work aisles. The right sliding racks can almost double the available storage space.
Even the design of the shelves themselves, the size of the shelves or the spacing between them, should be adapted to the goods to be stored on them. This can be planned right from the start, when designing them.
Picking.
This stage is usually crucial for businesses and takes the most time. What can be improved here?
It is necessary to start with the ergonomic arrangement of goods in the warehouse. It is important to consider the dimensions of the individual items, their individual storage requirements (temperature, required humidity, weight, etc.) and their location, considering the turnover rate.
When picking manually, it is worth ensuring that there are enough matching picking trolleys.
The process of packing and preparing shipments itself can be streamlined and shortened by using professional, ergonomic packing tables.
In order to improve communication between the different areas of the warehouse, it is worth designing and setting up an industrial conveyor system. It will automate the movement of goods and reduce the unnecessary routes that employees would have to take.
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