Keywords:ABC analysis, Warehouse layout design, Simulation
This research studied a warehouse of glass blocks manufacturing factory from storing to moving out from the warehouse. It was aimed to develop a new warehouse layout alternative to reduce material handling time. By collecting the data from the factory, it was found that the handling time of glass blocks was 0.7692 minutes per pallet, which exceeded the key performance indicator (KPI) of the factory that was 0.6 minutes per pallet. Therefore, ABC analysis was applied to classify the type of each glass blocks according to the amount of sales. After that, the existing warehouse layout was simulated by using Flexsim simulation software. The simulation showed that the handling time of glass blocks was 0.75 minutes per pallet. Then, dedicated storage and faster movers closer to the door principle were applied to design an appropriate layout along with simulated the scenarios of the current and proposed layout. The simulation showed that if the proposed layout had been implemented, the material handling time would have reduced from 0.75 minutes to 0.5455 minutes per pallet or reduced by 0.2045 minutes (27.27% reduction).
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