Our warehouse has 7 goods shelves. Each goods shelf has 4 layers. Each layer has 7 units. Each unit has a space of 240 cm x 80cm x 120cm.

The suppliers send us boxes of raw material. The sizes of the boxes are different. Because of this, the unit space cannot be fully utilized. I want to standardize the size of the boxes. What is your suggestion?

Our warehouse has 7 goods shelves. Each goods shelf has 4 layers. Each layer has 7 units. Each unit has a space of 240 cm x 80cm x 120cm.

The suppliers send us boxes of raw material. The sizes of the boxes are different. Because of this, the unit space cannot be fully utilized. I want to standardize the size of the boxes. What is your suggestion?

Hello darkafar,

Does your Purchase Order (P.O.) specify a particular box size/specification in which the raw materials must be delivered? If not, then you should discuss this matter with your supplier.

I do not know what's available in China, but you may want to look at commercially available standard size boxes. That's cheaper for you and your supplier. This may require you to adjust your racks and shelves. The benefit is optimization of storage space.

Here is another idea. Have you considered "returnable packaging?" Standard box sizes and no waste.

Stijloor.

Our warehouse has 7 goods shelves. Each goods shelf has 4 layers. Each layer has 7 units. Each unit has a space of 240 cm x 80cm x 120cm.

The suppliers send us boxes of raw material. The sizes of the boxes are different. Because of this, the unit space cannot be fully utilized. I want to standardize the size of the boxes. What is your suggestion?

darkafar,

You are free to decide the configuration of those boxes, provided they are available in the market.

If I were you, I would proceed in the following manner -

a. Amend the dimension of the box in the specification for that particluar part.
b. Have appropriate work instructions amended.
c. Perform some study to prove that the change doesnot affect product quality.
d. Talk to the supplier for the changed dimension and put it in writing, either through supplier agreement / formal letter.

If your goods or these boxes arrived through container trucks, check to make sure that the size you want is economical for stacking into containers - meaning there should not be too much empty spaces thus reducing the actual volume transported.

Our warehouse has 7 goods shelves. Each goods shelf has 4 layers. Each layer has 7 units. Each unit has a space of 240 cm x 80cm x 120cm.

The suppliers send us boxes of raw material. The sizes of the boxes are different. Because of this, the unit space cannot be fully utilized. I want to standardize the size of the boxes. What is your suggestion?

You can ask for any sort of packaging you think is appropriate, but you should expect the costs of it to be passed along. You might want to think about returnable packaging (http://www.returnables.com/) (packaging that can be reused) if you're going to standardize.

I just thought I would throw this out...

1. Some of the packaging suppliers have pretty robust software that can be utilized for maximization. Especially if they supply the packages, you tell them which ones you receive, how many you have, and what size shelf you have. It is pretty overwhelming for the human brain to calculate something like this. That's what computers are for.

Many packaging suppliers are professionals, and have some pretty sharp engineers. They are there to help you; let them!

2. You can build a simple linear program. Maximize the use of your shelves, subject to the constraints of the shelf lengths, # and size of the boxes that you receive.

3. Is it possible to purchase standard containers to go on the shelves? Then, you can find combinations of the suppliers packages to fit into those.

These are just a few more ideas next to the excellent ones already provided. If you cannot get them to change (or it is cost prohibitive), then I'm just thinking of ways you can make the best of your situation.

I want to standardize the size of the boxes. What is your suggestion?

Returnable containers have already been suggested. These have many advantages but their use would need to be measured against the costs of returning empties for re-fill, cleaning and repair between fills if necessary and purchasing a sufficient quantity to keep the pipeline flowing. Our returnables are dedicated to individual suppliers, but our customers have a series of standard sizes that aren't necessarily for only one supplier.

Something that hasn't been mentioned but may be a consideration for standardizing your containers (expendable or returnable): optimizing lot size for your processes. Our suppliers are asked to fill their containers with standard quantities that facilitate our production planning (which often does not fill a container to the top). If you are dealing with bulk ingredients rather than other kinds of components, you may want to dictate pre-measured amounts.

B.G. Wiehle