Warehouse Design & Operations Flashcards

What is the primary function of a 'pick-to-light' system in a warehouse?

Answer: Illuminates the pick location and displays quantity so pickers work without paper or scanner

Pick-to-light uses LED displays mounted on rack locations to guide pickers to the correct slot and quantity, improving speed and accuracy in high-density pick environments.

In warehouse slotting, ABC analysis classifies items by velocity. Which statement about 'C' items is correct?

Answer: C items are slow movers with low pick frequency, often stored in remote or high rack locations

C items represent low-velocity SKUs that are picked infrequently; placing them in less accessible locations frees prime slotting for high-frequency A and B items.

Which warehouse layout configuration maximizes storage density by eliminating individual pick aisles and using forklifts to drive into the rack structure?

Answer: Drive-in / drive-through racking

Drive-in racking eliminates side pick aisles by allowing forklifts to enter the rack lanes, trading selectivity for significantly higher storage density.

A warehouse operates a batch picking method. What distinguishes batch picking from discrete (single-order) picking?

Answer: A picker collects items for multiple orders simultaneously in a single trip through the warehouse

Batch picking consolidates multiple orders into one pick trip, reducing total travel distance at the cost of a sorting step afterward to separate orders.

What is 'cube utilization' as applied to warehouse operations?

Answer: The percentage of the building's total cubic volume that is actually used for storage

Cube utilization = (cubic volume occupied by inventory) ÷ (total available cubic volume) × 100, measuring how efficiently three-dimensional warehouse space is being used.

Under OSHA standards in the United States, what is the minimum required aisle width for forklifts in a warehouse when there is no two-way traffic?

Answer: At least 3 feet wider than the widest equipment or load, whichever is greater

OSHA 29 CFR 1910.178(e) requires aisles to be at least 3 feet wider than the largest equipment or load to ensure safe clearance.

Which receiving process involves counting and verifying inbound shipments at the dock door against the advance ship notice (ASN) before putaway?

Answer: ASN-confirmed receiving

ASN-confirmed receiving matches physical counts and item details against the supplier's advance ship notice, catching discrepancies before inventory is recorded as received.