WAR-030 Design of Warehouse Locations and Storage Area

1. A Basic Design of Receiving & Distribution Warehouse, Dispensary and Production Area

There are three (3) areas from which the material can be obtained to fill the production requirements of the raw materials or components:

CR    COOL ROOM – WAREHOUSE

FS    FLAMMABLE STORE – WAREHOUSE.

BS   BULK STORE – WAREHOUSE

1.1. The reject cage will be used only In case of rejected component/finished goods to store for some time before destroying or rework.

RC  REJECT CAGE – WAREHOUSE

There two Quarantine areas in the warehouse. One quarantine is located near to receiving doc and dedicated only for the incoming goods. The other quarantine area is dedicated for finished goods. Quarantines are used for:

Storing of incoming goods up to release by Laboratory.

Storing of Finished goods, completely separated from incoming goods, up to the release for distribution by Quality Assurance.

QIG    QUARANTINE (In-coming goods) – RECEIVING WAREHOUSE

QFG   QUARANTINE (Finished goods) – DISTRIBUTION WAREHOUSE

There are two booths in the dispensary area used either for sampling or dispensing of raw materials for production in an environmentally controlled area.

BOOTH 1       DISPENSARY

BOOTH 2      DISPENSARY

1.2. There are two Work in Progress areas (as mentioned before) where issued Raw materials and components are temporarily stored for line operators to check and receive according to Transfer Order.

WIP 1           DISPENSARY to PRODUCTION

WIP 2           DISPENSARY to PRODUCTION

WIP 3 is used only for returning materials/components down to warehouse bulk store. WIP 3 is only used for returning finished goods to QFG.

WIP 3           PRODUCTION to WAREHOUSE

WIP 4           PRODUCTION to WAREHOUSE

Figure: 2.1  A schematic diagram of warehouse, dispensary and production area

1.3. There is an Interim Production staging area inside the production zone in order to keep issued materials temporarily to use for the next batch (we will call here BPN).

IP    Interim production staging area.

If the leftover material/s (unprinted packaging components) are going to be used on the next BPN which is coming up shortly on the production schedules, (eg PVC film, foils, shrink film and shippers), these are to be kept in the Interim Production Staging area

2. Numbering system of Storage Units and Storage Bins

2.1. There are six types of Storage units used in both receiving and distribution warehouse.

QIG      – For storage of in-coming raw materials and component pending laboratory release. (on the left side of the drawing).

BS        – For storage of laboratory released raw materials and Components. (left side).

CR        – For storage of raw materials required special temperature monitoring (left side).

FS        – For storage of flammable liquids (left side).

QFG     – For storage of finished goods pending QA release for sale (right side).

FGS     – For storage of finished goods waiting for outside distribution (right side).

Each of the storage type has sufficient numbers of storage bins to keep the pallets. The numbering of these storage bins is done in a format of X-YY-ZZ,

Where,

X          Stands for each storage row named alphabetically (i.e. A – Z)

YY        Vertical parameter of storage bin rack identified by numbers

ZZ        Horizontal parameter of storage bin rack identified by numbers

Figure: 2.2            An example picture of warehouse storage units and storage bins.

3. Safety Procedure for Warehouse Racking

All new personal employed to work in the Warehouse are to be appropriately trained in order to understand the importance of storage racking safety and follow the procedure when working within any pallet racking system.

Major Damages of the Racking

If extensive damage occurs, personnel are not to step out of the forklift to assess the damage.  Personnel are to:

Stay within the forklift, drive away and notify all Warehouse personnel and the Area Manager immediately.

The Warehouse person who made the impact or discover the damage, with another staff member, will investigate the area immediately after the impact.

Secure the area by sectioning off and removing stock that is damaged from the racking.  Be sure to empty the whole bay. If a support beam is damaged both bays either side of the      damaged upright are to be emptied.

A Deviation Report has to be raised (see Topic 6 of Chapter 1)

The racking supplier is to be notified of the pending repair.

Minor Damages of the Racking

If minor damage occurs:

The Racking does not need to be emptied.

A Deviation Report is to be raised.

The Area Manager is to be notified in order to arrange a repair.

If it is a cross beam which has being damaged, the Store person can empty that bay and replace with spare racking the warehouse have available – as long as it is placed in the same area.

If Safety Clip is Found Dislodged or Broken

Goods must not be placed on that rack until the safety clip is replaced. This should be completed immediately.  It is the responsibility of the warehouse staff to inform and replace the safety clip straight away.

If no safety clips are on site, the area must be sectioned off and not used until more clips are supplied.

All Warehouse staff must be notified not to use the area until further notice.

Maintenance of Storage Racks

Safety clips are positioned to ensure that the racking support beams are in place.  All safety clips and racking (both cross-beams, side supports and safety guarding rails) are to be checked by Warehouse personnel on a monthly basis. The Warehouse Manager needs to ensure that the Warehouse staff check all the racking in all areas at the beginning of each month, using the following procedure:

By looking at each rack, determine if all the safety clips are in place.  Two members of the warehouse team will be lifted in the safety cage by a third team member who will then drive the forklift through each row of racking.

If there are any clips missing, these need to be replaced straight away.

If there are any damaged beams or side supports or damage to safety guarding/rails – they need to be identified and repaired immediately.

4. Summary of Changes