May 09, 2020

Receiving and put-away | Warehouse processes

These processes include receiving, pre-receipt, put-away, picking,storage, replenishment, value-adding services and despatch

Receiving, goods-in or in-handling may be a crucial process within the warehouse. Ensuring that the proper product has been received within the right quantity and within the right condition at the right time is one among the mainstays of the warehouse operation. These elements are often termed supplier compliance.
However, it's our contention that when goods have received the warehouse it's usually too late to rectify most receiving issues. We believe there are many steps that require to be taken before the particular act of receiving takes place.


First we'd like to make sure that the supplier presents the products to the warehouse within the most appropriate way. it's normally the customer who specifies the merchandise and thus might not have knowledge of the goods-receiving operation.
Our suggestion here is that the warehouse manager is additionally involved in specifying and agreeing the packaging, items per carton, cartons per pallet,

All too often we see items arriving at warehouses in unsuitable packaging that overhangs pallets, has incorrect or badly positioned labels and with the products packed in quantities that don't relate to selling-pack quantities. Our proposal here is that samples are ordered and despatched in their transit packaging to make sure full compliance.
All these problems take time to resolve and are better handled at the supplier before delivery.
Areas that require to be discussed both internally and externally before the
order being placed should include:
● size and sort of cartons;
● sort of transit packaging – cardboard, plastic, totes, metal stillages,
roll cages, pallets;
● palletized or non-palletized delivery of product;
● size (length, width and height) and sort of pallets, eg euro pallet,
four-way entry;
● specific labelling like product description, barcode and quantities;
● position of label on carton and pallet;
● carton quantities (inner and outer carton quantities, for example); and
● mode of transport, delivery quantity and frequency of delivery.
Delivery within the standard selling quantity is additionally crucial in assisting the manager to extend the speed of throughput and simplify picking. for instance ,
many companies still place orders on their suppliers in multiples of 12 yet most customers order in multiples of 10 thus causing considerable extra add computing quantities, opening cartons and re-packaging.


One of the most challenges for a warehouse manager is to match labour hours with work content. Handling a product the smallest amount amount of your time possible (labour touch points) results in reduced labour hours and as a consequence, reduced cost.
Depending on the operation, labour are often the only biggest cost within a warehouse. It are often between 48 and 60 per cent of the entire warehouse cost counting on the quantity of automation utilized. it's also the foremost difficult cost to regulate .
In-handling makes up approximately 20 per cent of the entire direct labour cost within a retail warehouse.


Prior to the particular receipt variety of processes got to happen . The first
step is to make sure that suppliers deliver into the warehouse once you decide, not
when it suits them. there'll be exceptions to the present . for instance , it's difficult
for parcel delivery companies to stick to booking times due to the character
of their deliveries; however, pallet and full-load delivery companies expect to
be given specific delivery times, albeit this is often not their preferred option.
By providing delivery times for every supplier or their subcontractors, you
are on top of things and ready to match your work hours to figure content. A booking-in
or dock scheduling system must be introduced. Many of today’s WMS have
a dock scheduling module lately however an Excel spreadsheet will suffice.
Initially you would like to make a decision on once you are getting to receive products into
the warehouse. Are you getting to have deliveries throughout the day or limit
them to a morning shift, for example?

On arrival, the vehicle details got to be checked against the booking reference and therefore the vehicle allocated a loading bay or location within the yard. Any vehicle seals got to be checked against the delivery paperwork. before offloading temperature-controlled vehicles, the temperature history
of the vehicle whilst in transit must be checked, along side the present
temperature of the products . Once the vehicle has backed onto the acceptable bay or has been positioned within the yard for offloading from the edges , the in-handling team should
have appropriate labour and equipment handy , to efficiently manage the
offloading process. Where vehicles are unloaded within the yard this usually necessitates the utilization of
two lift trucks, one to unload the trailer and another to place the merchandise away within the warehouse.


Once the products are offloaded, you would like to make a decision whether or not they got to be checked before put-away. the perfect scenario is to maneuver inbound goods directly from the loading bay to the cargo area or despatch area if goods are cross docked.

Cross docking

The goal of most warehouses is to extend throughput rates and reduce the quantity of stock held. Cross docking may be a process where products are moved directly from goods-in to the despatch bays. This replaces the necessity to put the merchandise into store and any subsequent picking operation.
Cross docking needs the complete support of suppliers on how they present the merchandise . This includes clear labelling and advance notice of arrival along side accurate, on-time delivery.
Cross docking requires systems to spot the merchandise that must be cross docked and a process must be in situ to acknowledge and alert the staff.
Once checked in, the products should be taken on to the despatch area and their floor or temporary rack location recorded on the system, alerting staff that the merchandise is now awaiting despatch. the small print must be recorded so as to supply an audit trail.


Depending on the merchandise , there might be a requirement to record quite just the quality data like product code, description and quantity on arrival.
Other information could include batch or lot numbers and serial numbers. Barcode scanning, which we'll check out within the following chapters, is right for this sort of knowledge capture.

Quality control

It is accepted that certain products would require more stringent checking on receipt. These include high-value items, food, hazardous goods, temperature-sensitive product and pharmaceuticals. New suppliers will also fall into this category.
An area on the brink of the receiving bay should be put aside to identify check items on arrival. This needs to be done as promptly and as efficiently as possible so as to avoid congestion and to get the products onto the system quickly. If there are issues, the things got to be taken to a selected quarantine area or, if space is a problem , to the cargo area – but must be identified as defective or awaiting the results of tests. Most WMSs are ready to block access to products on the system, making them unavailable for selecting until cleared purchasable . A physical sign at the situation is a further failsafe.


Many of today’s WMSs allocate product locations beforehand and instruct the operator on where to put the products . This can be on to the despatch area if the merchandise is to be cross docked as discussed above, to the pick face as a sort of replenishment or to a reserve or bulk-storage location.
In order for this system to work effectively, a great deal of information needs to be programmed into the system. This includes the following:
● size, weight and height of palletized goods;
● results of an ABC analysis or slotting, where fast-moving goods are
placed closest to the despatch area (an area we will cover later);
● current order data;
● family product groups;
● actual sales combinations;
● current status of pick face for every product;
● size of pallet locations; and
● weight capacity of racking.

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