Background of the Warehouse Industry.- 1 Warehousing: Origins, History and Development.- History.- Warehousing in America.- Role of the Independent Warehouseman.- Financial Security Aspects.- Role in Mass Production.- From Terminal to Distribution Center.- The Emergence of Business Logistics.- The Rise of Professional Associations.- Trade Associations.- 2 Warehousing in Today's Economy.- The Business Environment.- Freight Consolidation.- Real Estate as an Investment.- Warehouse Locations Shift.- 3 The Functions of Warehousing.- Six Functions of Warehousing.- Three Warehousing Alternatives.- Cost Structure.- A Contract to Control Risks and Costs.- Changing Values of Warehousing.- Space.- Equipment.- People.- 4 Warehousing Alternatives the Make or Buy Decision.- Corporate Financial Policy.- Labor Relations Policies.- Strategic Decisions.- The Final Decision.- Public vs. Contract.- The Economics of Third Party Warehousing.- Bonus Incentives.- Other Factors.- The Elements of Warehouse Management.- 5 Communications.- Hard Copy Versus Voice.- Public Warehousing Forms.- Damages.- Real-Time Inventory Control.- Circulation of Stock Status Information.- Effective Order Picking.- Faulty Communications Equal Wasted Effort.- Complaints.- Standard Procedures.- Uniform Communications-A New Development.- Uniformity for Warehousing.- System Priorities.- 6 Packaging and Identification.- Functions of a Package.- How the Package Affects Warehousing.- Effect on Stacking.- Packaging for Unitization.- Identification.- Container Handling.- Package Design.- Efficient Packaging-A Joint Responsibility.- A Series of Compromises.- 7 Transportation.- Location.- Effects of Transport Modes.- Freight Rates.- Transit Time.- Private Fleets.- Warehouse Freight Consolidation.- Reducing Transport Costs in the Deregulation Era.- Reducing Freight Costs.- Transportation Brokerage-A Useful Tool.- The Second Industrial Revolution and Its Effect on Transportation.- 8 Accountability.- Title.- Inventory Responsibility.- Product Liability.- Insurance.- Summary of Claims Procedures.- 9 Starting-Up or Moving a Warehouse Operation.- Initial Planning.- Cost Considerations.- Transportation.- Taxation.- Insurance on Goods in Storage.- To Move or Not to Move.- Timing Can Be Critical.- Estimating the Cost of Moving.- How to Load the Trucks.- Cost of Transferring the Load.- How Long Will It Take?.- Deciding to Continue Services or Suspend Operations for the Move.- What to Move.- Customer Communications.- Other Communications.- Opening the Relocated Warehouse.- Planning the Opening of the Distribution Center.- Writing a Warehouse Operating Manual.- 10 Warehouse Performance Audits.- Tracking Accuracy.- Account Profitability.- Qualitative Performance Ratings.- Other Performance Guides.- Real Estate Aspects of Warehousing.- 11 Finding the Right Location.- Reasons for Site Seeking.- Location Theories.- Outside Advisers.- Requirements Definition.- Comparisons From Published Sources.- The Final Selection Process.- 12 Building, Buying, Leasing, or Rehabilitating?.- Acquisition.- A Worksheet for the Buy/Lease Decision.- Assumptions.- The Rehabilitation Alternative.- Rejuvenating Warehouse Roofs.- Rejuvenating Warehouse Floors.- 13 Construction.- Test Borings.- Government.- Storm Water Management.- Utilities.- Layout Design.- The Contract.- Risk Management.- Roofs.- Fire Protection Systems.- Heating.- Roads.- Docks.- Wear and Tear.- Floors.- Rails.- Illumination.- Walls.- Landscape.- 14 Planning for Future Uses.- Design Structure for Versatility.- Changes in Basic Function.- Internal and External Changes.- Planning Warehouse Operations.- 15 Space Planning.- Sizing the Warehouse.- Storage Requirements.- Interaction of Storage and Handling Systems.- Stock Location Systems-Fixed versus Floating Slots.- Family Groupings.- A Locator Address System.- Cube Utilization.- Lot Size.- Reducing Aisle Losses.- Reducing Number of Aisles.- Managing Your Space.- 16 Planning for People and Equipment.- The Process of Making Flow Charts.- The Best Sequence?.- 'What If' Questions.- Personnel.- The Critical Role of the Supervisor.- Planning for Equipment Use.- 17 Contingency Planning.- Strategies.- Trigger Points.- Planning for the Impact of Strikes.- -Your Own Firm' s as Well as Others'.- Strike Against Suppliers.- Strikes Against Customers.- Trucking Strikes.- Charting the Planning Process.- Planning Steps.- 18 Postponement.- Background of Postponement.- Types of Postponement.- Postponement of Commitment.- Postponement of Title Passage.- Postponement of Branding.- Postponement of Consumer Packaging.- Postponement of Final Assembly.- Postponement of Blending.- Increased Warehouse Efficiency.- Potential Challenges.- Postponement in the Warehouse.- 19 Strategic Planning.- What Is It?.- How to Start.- Corporate Strategy as a Morale Builder.- Production Changes.- Strategic Thinking in the Public Warehouse.- Financial Changes.- Planning Warehouse Networks.- 20 Selecting a Public Warehouse.- The Preparatory Phase.- The Investigative Phase.- Evaluating Quality.- The Decision.- Protecting the Warehouse Operation.- 21 Preventing Casualty Losses.- Types of Casualty Losses.- Controlling Fire Risks.- Hazard Ratings for Stored Merchandise.- Wind Storm Losses.- Flood and Leakage.- Mass Theft.- Vandalism.- Plant-Emergency Organizations.- New Developments in Fire Protection.- The Importance of Management.- 22 'Mysterious Disappearance'.- Electronic Detectors and Alarms.- What About False Alarms?.- Door Protection Alarms.- Grounds Security.- Seals.- Storage Rack.- Restricted Access.- Marketability of Product.- Hiring Honest People.- Using Supervision for Security.- Procedures to Promote Security.- Customer Pick-ups and Returns.- Security Audits.- 23 Safety, Sanitation and Housekeeping.- Improving Safety in Lift Truck Operations.- Action Steps to Improve Safety.- Sanitation.- Housekeeping.- Damage Spreads.- Personal Appearance-Part of Good Housekeeping.- Effect on Employee Morale.- Effects on Customer Service.- A Source of Shame.- Impact on Safety.- A Housekeeping Checklist.- 24 Contracts and Liability.- The Changing Role of the Warehouseman.- The Insurance Problem.- Customer's Contracts.- Liability Limitation.- A Meeting of the Minds.- 25 Verification of Inventories and Cycle Counting.- Purpose of Inventories.- Inventory Carrying Cost.- Benefits of Improvement.- Problem Areas.- How Can a 'Physical' Be Improved?.- Incentives.- Managing the Job.- Involve the Whole Team.- Getting Organized.- Advance Preparation.- The Importance of Cutoff.- Zones.- Arithmetic Aids.- Controlling the Count.- Reconciliation.- Eliminating Inventory Errors by Cycle Counting.- What Does the Future Hold?.- The Human Element.- 26 Orientation and Training.- Training.- Some Training Examples.- Retraining for New Equipment.- Films and Video Tape.- Operator's Guide.- Mentoring.- Record Keeping.- Goals of Training.- 27 Labor Relations.- Creating a Union-Free Environment in the Warehouse.- An Example.- Public Warehousing Alternative.- Public Warehouse Strikes.- Using Subcontractor Warehouse Services.- Transportation Strikes.- Inventory Hedging.- Turning from Union to Union-Free.- Pre-Employment Screening.- Employee Complaints.- The Role of the Supervisor.- Arbitration Standards Pertaining to Discharge.- The Essence of Union-Free Management.- Summary.- 28 Motivation.- Output Criteria.- Feedback.- Skills.- Balance of Consequences.- Participatory Circles.- Developing a High-Performance Work Culture.- A Case Example of Participative Management.- Warehouse Incentives.- The Importance of Listening.- 29 Maintaining and Improving Performance.- Development.- Discipline.- Peer Review-A New Approach to Discipline.- New Personnel.- Pre-Employment Investigation.- The Interview.- Drug and Substance Abuse in the Warehouse.- Probation.- Personnel Management.- The Labor Contract.- Wage Reviews.- Job-Performance Appraisal.- Attitude Surveys.- Promotion From Within.- Pride in the Company.- Productivity and Quality Control.- 30 Making Warehousing More Efficient.- 1. Improve Forecasting Accuracy.- 2. Free Labor Bottlenecks.- 3. Reduce Item Handling.- 4. Improve the Packaging.- 5. Smooth the Flow Variation.- 6. Set Improvement Targets.- High-Priority Goals.- 7. Reduce Distances Traveled.- 8. Increase the Size of Units Handled.- 9. Seek Round-Trip Opportunities.- 10. Improve Cube Utilization.- Technology to Achieve Increased Efficiency.- 31 Measuring Productivity.- What to Measure?.- Historical Standards.- Predetermined Standards.- Observation Techniques.- Stopwatch Standards.- Multiple Regression Analysis.- Uses of Regression Analysis.- Quality Measurements.- Common Methods of Measuring Productivity.- Guidelines for Measurement Systems.- 32 Scheduling Warehouse Operations.- Eliminating Delay.- Truck Dock Schedules.- Backlog.- Scheduling for Peak Demand.- Real Time Information and Scheduling.- Stock Locations and Scheduling.- Aids to Scheduling.- 33 Customer Service-Its Role in Warehousing.- 1. Is This Warehouse Necessary?.- 2. Phone Orders and Toll-free Numbers.- 3. Consolidations.- 4. Free Shipping.- 5. Classify Orders by Size.- 6. Backhaul.- 7. Accuracy in the Warehouse.- 8. Keep Communications Channels Open.- 9. Seasonality and Sales Contests.- The Customers Pay the Bills.- Summary.- 34 Improving Asset Utilization.- Space Utilization.- Energy Utilization.- Equipment Utilization.- The Equipment Utilization Ratio.- Improving Performance.- Lift Truck Rebuild Program.- Key Points of the Rebuild Program.- The Value of the Program.- Inventory Performance.- The Management Factor.- Why Measure?.- Danger Signals.- Inventory Turnover and Distribution Analysis.- Case History.- An Action Plan-And Potential Benefits.- Summary.- 35 'Just-in-Time'.- JIT in Manufacturing.- JIT in Service Support.- JIT As a Merchandising Strategy.- JIT in Warehousing.- 36 Identifying and Controlling Costs.- Three Cost Centers.- Space Utilization.- The Effect of Product Turns.- Other Performance Specifications.- Measuring Productivity.- A Cost Calculation Example.- The Throughput Rate Concept.- Adjustments.- Summary.- 37 Management Productivity.- Defining Management.- Why Warehousing Is Different.- The Effective Manager.- Measurement Tools for the Manager.- The Critical Tasks of a Manager.- The Manager's Hardest Job.- The Buck Stops Here.- How Good Are Your Warehouse Supervisors?.- The Supervisor Promoted from Within.- The Importance of Clarifying Expectations.- Putting It All Together.- 38 Reducing Errors.- The Value of Order Checking.- Order Picking Errors.- Order Taking Errors.- A Good Item Location System.- Clear Item Identification.- Clear Description of Quantity Required.- 'Good' Order Picking Document.- Order ldentification.- The Order-Filling Form.- Other Factors to Consider.- Multi-Line Order Filling.- Personnel Factors.- Identification With Work.- Posting Error Rates.- Using Case Labels.- 'Picking Rhythm'.- Summary.- Handling of Materials.- 39 Receiving and Shipping.- Receiving.- Shipping.- Dealing with Shippers Load and Count (SL&C).- Controlling Damage Claims.- 40 Specialized Warehousing.- Temperature Controlled Warehousing:.- The Essential Differences.- Hazardous Materials Warehousing.- State and Local Building Inspectors.- Fulfillment Warehousing.- Summary.- 41 Order Picking.- Quality in Order Picking.- Order-Picking Forms.- Inventory Relationship to Order Picking.- Order Picking Systems.- Fixed Versus Floating Slots.- Order Picking Methods.- Discrete Versus Batch Picking.- Zone System of Picking.- Designing Your Order Picking System.- Modeling Order Picking.- Safety.- Hardware.- Summary.- 42 Equipment: Storage and Live Storage.- Defining the Job.- Improving Storage with Racks.- Reducing Number of Aisles.- Other Types of Pallet Rack.- Live Storage-Gravity Flow Rack.- When to Use Flow Racks.- What Flow Racks Will Not Do for You.- Using the Carousel.- Stock Layout in a Carousel.- Justifying the Carousel.- Conveyor Systems.- Types of Conveyors.- The AGVS Alternative.- Summary.- 43 Forklifts and Other Mobile Equipment.- Choosing a Lift Truck.- Lift Truck Attachments.- Order Picking Trucks.- Justifying Narrow-Aisle Equipment.- Strategic Considerations.- Automatic Guided Vehicle Systems.- System Integrators.- What to Look For in Mobile Equipment.- 44 Approaching Automated Handling.- Strategic Planning.- Ergonomics.- Robotics.- Conventional Warehouse System Vs. High Rise.- The Building.- Storage Equipment.- Materials Handling Equipment.- Back-up Systems and Maintenance.- Security.- Computer Requirements.- Coping with Change.- The Future of Automated Systems.- Conclusions.- 45 Unit Loads.- Pallets.- Parts.- Types of Pallets.- Types of Wood Employed.- Performance Specifications.- Box Pallets or Pallet Containers.- Slip Sheets.- Performance Specifications.- Building and Handling Unit Loads.- Loading Unit Loads on Trailer or Rail Cars.- Equipment to Handle Unit Loads.- A Case Example of Slip-sheet Handling.- The Potential Is Great.- 46 Dealing With Damage.- Causes of Damage in Physical Distribution.- Causes of External Damage.- Disposal of Carrier Damage.- Concealed Damage.- Warehouse Damage.- Reducing Warehouse Damage.- Recooperage and Repair.- Protecting Damaged Merchandise.- Storage of Damaged Products.- Loss and Damage Guidelines.- Damage Control Ratios.- Damaged Loads Ratio.- Inventory Shrinkage Ratio.- A Management Checklist for Damage Control.- Handling of Information.- 47 Clerical Procedures.- Customer Service Standards.- Location of Clerical Center.- Office Environment.- Organizing the Clerical Function.- Interaction with Marketing.- Manual and Electronic Data Processing.- Control of Automation.- Measuring Clerical Costs.- Management Information.- 48 Computer Hardware.- Micro, Mini, Mainframe.- Computer Jargon.- Portable Data Collection Terminals.- Purchasing Hardware.- Hardware Development.- Applications in Public Warehousing.- 49 Software for Warehousing Operations.- Warehouse Floor.- Customer Service.- Management Information.- Transportation.- Electronic Data Interchange (EDI).- Cost Analysis Programs.- Program Costs.- The Requirements Definition.- The Role of the User.- Finding Software Sources.- Evaluation.- Demonstration.- Flexibility and Control.- The Vendor.- Training.- 50 Electronic Identification.- Bar Codes-What They Are and How They Work.- Scanners.- Contact and Non-Contact Readers.- Printing Bar Codes.- Using Bar Coding in a Warehouse.- Benefits.- Using the System.- The Future of Electronic Identification.- Appendices.- Appendix 1.- Uniform Commercial Code.- Appendix 2.- Awa Booklet of Depositor-Warehouseman Agreements.- About the Author.
