The warehouse is designed to be environmentally

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The warehouse is designed to be environmentally friendly with such features as:Solar panelsStorm water collection15% roof lightsAutomated lighting control systemsRECEIVINGMost goods are received packed in cartons on pallets. These are moved by reach truck onto a lift which raises each pallet to the appropriate handling height so that the goods can be extracted, checked and placed into plastic tote bins. There are a total of 52 decant workstations on raised platforms. Any new product lines are weighed, scanned for their cubic measurements and photographed at this stage. The tote bins are then normally transported by conveyor directly to the ‘miniload’ automated storage and retrieval system (AS/RS) or order storage and retrieval (OSR) storage areas (see below). In total, there are over 10 kilometres of conveyor connecting the different operations.Some goods are received in tote bins, in the correct quantities, and pre‐advised elec-tronically by the supplier using an advance shipping notification (ASN). The pallets containing the tote bins are moved by a powered pallet truck (PPT) to depalletising robots which unload the pallets and place the tote bins onto a conveyor, for transport to the AS/RS or OSR.Goods that are not required for picking in the immediate future are moved on pallets (or tote bins placed on pallets first) and transported by reach truck to the narrow‐aisle stor-age area. Any pallets that have not been given a licence plate number (LPN) by the sup-Mangan-p02-cs01.indd 2403/22/2016 4:40:55 PM
CASE STUDIES JOHN LEWIS PARTNERSHIP 241plier are provided with one at goods receiving for subsequent identification. All receiving operations are conducted with the aid of radio data terminals.STORAGEThe narrow‐aisle storage area comprises 26×1.75m aisles, operated by wire‐guided narrow‐aisle turret trucks. ‘Bus‐bars’ are fitted to some aisles for battery recharging so that the trucks can operate continuously over multi‐shifts. There are a total of 22,500 pallet locations. When the goods are required for replenishment to the tote bin storage areas, they are moved to the tote bin filling platform (or directly to the bin storage area if they are already in tote bins). This narrow‐aisle bulk storage area is thus used for replenishing the tote bins storage areas described below. There is also a separate haz-ardous narrow‐aisle area with mesh protection.The AS/RS is used to store tote bins of fast‐ and slow‐moving lines. There are 13 cranes (one per aisle) capable of moving two bins at a time. The storage system is double‐deep. The throughput rate of the cranes is 125 bins per crane per hour (both in and out). The tote bins are then placed onto a conveyor for movement to the picking operation.

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