Layout evaluation to improve picking process in a boat company warehouse

Abstract

The high concern of companies and their commitment to the reduction of lead times, combined with the growing variety of products, which is increasingly evident, is of extreme importance. Also important is the focus on improving logistical operations, many of which are registered within the warehouse itself, both for raw materials and finished products. This work aims to analyse and suggest improvements in the layout of the raw material warehouse in a yachts production company, to reduce the picking time process. For this, it was necessary to understand if the layout warehouse was the most appropriate, or if it had to be reorganized in a different way. Each picking list is assigned a collaborator and has several different stations, consequently, representing different parts of the production of the boat. Internal and external recognition of the company was made so that it was possible to understand working methods and analyse all the flows related to the four production lines. Then the collaborators were monitored to understand their methodologies and the way they worked, as well as the main difficulties they felt. The data relating to the distances and picking times, of the respective boat models selected according to the production process, were collected, and analysed and a new layout was proposed. According to the results obtained with the proposed layout, the picking time was reduced by about 23%, the picking distance was reduced by about 32% and, at the same time, the picking flows and materials organization were improved, responding to the company objectives. In conclusion, the company has an advantage in modifying the layout of the warehouse oriented to the layout per station.