A WAREHOUSE SYSTEM DESIGN FOR CORRUGATED PAPER BOX FACTORY

Abstract

This research is a design of a warehouse system for a corrugated box manufacturer using principles of stock planning and storage area design, warehouse management system, and a systematic layout planning: SLP. Since the original warehouse lacks an effective put-away and picking management system, a lot of times was wasted in searching and relocating goods in an unordered stock. This project emphasizes the study of a design and development of a storage area and warehouse management system using a case study of the corrugated paper box factory.

For the design of a 24x20 square meters area to be able to store a maximum of corrugated boxes using pallet support, the author has made two layout designs to be compared. The 45-degree design can hold 106 pallets whereas the 90-degree design can hold 136 pallets, which account for 22.52% and 34.28% of the total area and are able to store goods for 5 and 7 days, respectively. Then the better 90-degree layout has been selected as a prototype for the factory’s warehouse management system by further designing a put-away and picking system with the following documents: 1. Stock receiving form, 2. Stock cards, 3. Merchandise tags, and 4. Merchandise picking form. The Microsoft Excel 2003 forms have also been designed for recording and searching, which make the system less prone to errors and increase inefficiency.