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SECOND
PLACE WINNER

University
Student Design Team
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Trever Murcko,
John Rudy, Jarrod Sharpe, Chris Turnbill
A
powerful warehouse management system and judicious use of automation
lend this winning facility both efficiency and flexibility
THE
DETAILS
- Cross-docking
expedites shipping and reduces the amount of storage space and
equipment required
- Rack-mounted
light displays in the forward picking area help expedite the picking
process and minimize picking errors
- Elevated
sortation system accommodates extra space required by conveyor
pushers and frees up floorspace below
- Mezzanine-based
picking system takes advantage of overhead space and accommodates
additional pick faces
- Automated
sortation system facilitates the replenishment of case flow racks
for easy, localized order picking
- Light
displays in pallet building area alert driver when a sufficient
quantity of merchandise is ready to be palletized
he large manual
warehousing system that the current facility employs will not support
the five-year increase in volume without large increases in manpower
and space,” says the Penn State Student Design Team. “In addition,
tracking and sortation are run in a confusing manner that results
in larger cycle times and low turnover.” The team’s proposed design
is governed by a high-complexity WMS, which makes use of scanning
and automatic sortation to route the expected increase volume of
product efficiently and eliminates the need for an overflow warehouse.
The Material
Flow
Incoming merchandise travels by conveyor directly from trucks to
a forward picking or reserve storage area, or is cross-docked directly
to an order-building area. High-volume pallet-loads are assigned
to a dedicated location in pallet flow racks, all other SKUs are
stored randomly in pallet racks. Cases travel by conveyor to flow
racks in a mezzanined picking system. Picked items are placed on
the sortation conveyor and diverted to the appropriate pallet building
location, where orders are consolidated and palletized for shipment.
THE
FACILITY STATS
Facility size (sq
ft): 162,000
Capital investment cost:
$8.6M
Annual facility operating cost:
$4.8M
Number of employees:
66
Equipment employed: Conveyors,
pallet and flow racks, industrial trucks, mechanical dock levelers,
WMS
Noteworthy features: In-truck
conveyor system at receiving dock, pick-to-light system in forward
picking, use of FactoryPlan software for layout and design work |
FACILITY
LAYOUT

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NISSAN
FORKLIFT CORPORATION, NORTH AMERICA
THE NISSAN INDUSTRIAL EQUIPMENT DIVISION of
Nissan Motor Company Limited began manufacturing forklifts in Japan in
1957, and has been selling forklifts in the United States since 1965.
In 1988, Nissan Industrial Equipment purchased Barrett Industrial Trucks,
a manufacturer of industrial equipment in the Chicago, Illinois area since
1914. This purchase made Nissan the first Japanese company in North America
to manufacture and distribute all five classes of industrial trucks. The
first Nissan forklifts were assembled in Marengo, Illinois in May of 1988.
From that small beginning thirteen years ago, Nissan has seen sales and
production grow to over 15 times that first year’s production number.
In 1993, the consolidation of operations was completed in Marengo and
a new corporation was formed, Nissan Forklift Corporation, North America,
manufacturing the Nissan Forklift and Barrett Industrial Truck brands
for distribution to the North American market, and export to other global
markets. Nissan Forklift Corporation employs 530 full time employees in
their 400,000 sq. ft. facility. The Nissan facility in Marengo is the
largest of three Nissan forklift production facilities in the world. Nissan’s
forklift operations have consistently posted operating profit for the
company. Its Industrial Machinery Division employs 1,730 people in Japan,
Europe, and the United States, and approximately 30,000 units were sold
last year in more than 60 countries worldwide. Nissan Forklift Corporation,
North America is a full line supplier of engine powered forklifts, electric
sit-down and stand-up riders, narrow aisle reach trucks, electric pallet
trucks, electric tow tractors, electric walkie stackers, and manual pallet
trucks in the Nissan and Barrett Industrial Truck brands. Both products
are sold and serviced through a North American dealer network with more
than 140 locations.
Contact
us at
(815) 568-0061
or visit us on the Web at www.nissanforklift.com
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