DESIGNING WAREHOUSE FOR A MOTOR MANUFACTURING COMPANY

Abstract

This research designed a warehouse of a motor manufacturing company in Bangkok in order to support the growth of the company, in terms of holding capacity and operational performance. It began with the study on problems in the existing warehouse and generated solution concepts. The main causes of the problems were improper material storage equipment, inefficient warehouse layout and poor warehouse operation. The design process began with creating a conceptual design to take care of the problems and the company requirements. After that, a detail design was created with considerations on product categories, warehouse layout, the use of material handling equipment and material storage equipment, velocity based layout, new warehouse operations, product numbering, signage and shelf labels, security operations, warehouse safety, dead stock policy and 5S. Six key performance indicators were used to evaluate the design.

There were several improvements after implementing the design. The warehouse capacity was increased by 48.42 percent. The average time of all operations decreased by 33.33 percent. The product picking accuracy increased by 2 percent. The number of injured staff reduced from 3 persons to 0 person in the first three months. The loss and damaged product was reduced by 87.5 percent. Customer's satisfaction measured by the returning of new customers increased by 14.28 percent.