Course Outline

Classes begin at 8 a.m. each day.

Classes end at 5 p.m. on the first two days and at 3:30 p.m. on the final day.

Day 1

1. Introduction
   • Typical approaches to layout planning
   • Three fundamentals of layout planning
2. Case Exercise in Layout Planning
   • A six-step simplified planning procedure
   • Relationship charts and diagrams
   • Hands-on case exercise in warehouse layout
3. Systematic Layout Planning (SLP)
   • The four phases of every layout project
   • Systematic planning procedures
   • Gathering and projecting key input data
4. Profiling and Inventory Analysis
   • Activity and order profiles
   • Inventory profiles
   • Zoning and picking methods
   • Matching your methods to inventory levels and flows
   • Storage capacity calculations
5. Handling and Storing Equipment
   • Unit load handling and storage
   • Case and item picking and storage
   • Simple and complex equipment
6. Case Exercises in Methods Selection
   • Discussion problems on storage, handling, and order-picking

Day 2

1. Classical Layouts and Flow Patterns
   • Commodity, activity, and other storage zones
   • Basic flow patterns and their benefits
   • Charting your operations
   • Defining your activity areas
2. Flow of Materials Analysis
   • Ways to measure and visualize material flow
   • The quantified flow diagram
   • Guided application in flow analysis
   • Combining flow and other-than-flow relationships
3. Estimating Space Requirements
   • Five ways to establish space requirements
   • Short-range and longer-range space projections
   • Case exercises in estimating space requirements
   • Balancing space required to space available
4. Facilities Planning Issues
   • Adjusting for physical features of the facility
   • The impact of utilities, lighting, HVAC, and other specialized requirements
   • Rack and aisle orientations
5. Case Exercise in Warehouse Layout and Materials Handling
   • Team exercise to improve an existing layout
   • Rearrange to reduce material handling effort
   • Layout considerations other than material flow

Day 3

1. Evaluation of Alternative Plans
   • Costs and intangibles
   • How to select the best overall layout
2. Detailed Layouts
   • Rack storage areas
   • Shelving arrangements and slotting
   • Dock areas
   • Application of SLP to equipment layout
3. Case Problem in Distribution Center Planning
   • Application of techniques from days 1 and 2 to a distribution center expansion
   • Organizing the project
   • Developing a preliminary arrangement
   • Integrating storage and handling methods
4. Case Problem Continues
   • Improving the preliminary plan
   • Responding to changing and unforeseen requirements
5. Organizing Your Layout Project
   • Recap of phases, steps, and planning documents
   • Working forms and templates for your next project
   • What top management wants to know

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