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SECOND PLACE WINNER

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Student Design Team


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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NOVEMBER 2002
table of contents
Introduction
Today's Engineering Students, Tomorrow's Facility Designers
 
Winners

First Place
Virginia Tech


Second Place
Penn State University


Third Place
University of Florida

Honorable Mention
Ohio University

Honorable Mention
New Mexico University

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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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