Through Flow

‘Through’ flow happens when separate loading bay facilities for outbound and shipping are provided, often at opposite ends of a warehouse.

It is better to adopt a 'through' flow when a warehouse is connected to a production plant, or when there is confusion between goods in and goods out, or when the goods inwards and dispatch vehicles are different (e.g. platform height, nature of unit load)

Advantages
· It does not cause any confusion
- Workers know where is the loading/unloading bay
- Workers will not be confused as where the goods should head

Disadvantages
· Necessitates all goods travelling at full length of the building
· Environmentally less easy to control
· Less flexible in the event of future expansion and operationally

'U' Flow

‘U’ flow occurs when the goods receipt and dispatch functions are located at the same end of a warehouse building. It enables popularity storage systems to be used to minimize movement by locating fast-moving product lines close to the loading bays.

Advantages
· Better utilization of dock space· Better utilization of handling equipment
· Lesser total area required· More flexibility
· Better control of security and of environment

Disadvantages
· Causes confusion
- Workers might get confused as where to move the goods to
- Workers might get the goods to the wrong bay (loading or unloading)
. This will cause decrease in productivity

External layout design

Other than planning and designing for internal layout design, the external part of the layout is also equally important.

-Size and configuration of the site (to accommodate vehicles and facilities)

-Site access (adequate for different types of vehicles and volume of vehicles)

-Local authority plans (any plans that could affect proposed warehouse by government?)

-Site details (the drainage system and ground characteristics)

-Financial considerations (rates of rental/other overhead cost/able to apply loans?)

-Legislation and local regulations (public holidays/what can do, what cannot do)

-Building factors (is there any existing buildings? can be use as warehouse?)

Usefulness

· It is to ensure a smooth flow of goods and people in the warehouse. By having a smooth flow, there will be minimal congestion and it will increase productivity. There will also not be any delay in the production and this will either maintain or increase customers’ satisfaction.

· A well planned layout in the warehouse can ensure safety and security of both goods and people in the warehouse. With a good layout design; goods, equipment and people will have their own ‘path’, this will ensure no bumping into each another during operation. This will lessen the risk of goods falling and hitting the workers in the warehouse.

· It will make work easier for the workers to access to goods in the warehouse with a good layout design. Usually in a warehouse, different types of goods are placed at different locations. By having a good layout, workers will have ease of access to the goods and the accuracy of goods location, inventory level and identification.

Constraints

· Planning a layout for a warehouse is like a one-time thing. It is not flexible and can be changed to adapt to the different types of goods the warehouse stores. There is no changing of layout design from time to time as it is a ‘fixed’ project. Minimal alterations might be possible, but for example; changing the main storage area to the marshalling is nearly impossible. Not only you need to consider for the internal design plan, the external design plan must also be put into considerations.

· Planning must be very accurate; otherwise it might sabotage the entire warehouse effectiveness and efficiency. For example; if the warehouse needs to use conveyor belts, the planning of where to install the conveyor belts are very important as once the conveyor belts are installed, there cannot be any changed.

Questions

1: So why do you need to plan for the external layout to achieve effective warehousing?

Answer: To achieve effective warehousing, it is necessary to combine and plan carefully for both internal and external layout. Let us give you an example on site access; the internal layout is smooth, but the external layout are having problems like, the height of the shelter is too low and the trucks will hit it if it enters. Therefore, workers need to move the goods manually to the trucks and it will decrease productivity, takes up more time.

Thank you Wenkai for your question!

2: When to use 'through' flow and when to use 'U' flow?

Answer: Use 'U' flow when the loading/unloading bays are adjacent to each other. It ultilise more of the warehouse space. Use 'through' flow when the loading/unloading bay are opposite of each other. It will cause lesser confusion and the workers will know where the goods should head without making any mistakes.

Thank you Joanne for your question!