Industrial and Manufacturing Engineering Department
BS in Industrial Engineering
This report presents the warehouse redesign of Sunrize Tackle Inc's main facility. Located in Santa Barbara, California, Sunrize Tackle is a manufacturer of premium swimbaits and other fishing tackle. They currently face a problem as their product is undergoing an alteration in packaging, and will not fit into the current space available. The objective is to develop an alternative layout and plan for the facility that improves flow of product and employees, reduces inefficiencies in daily operations, and can adapt to fluctuations in demand and sales. The current layout and operations were reviewed, and three major components which affect the majority of processes were identified. The rack formation, rack and shelf type, and classification system were all identified as areas of potential improvement. Alternatives to the current were produced for each area, and then compared against the each other. The best of the options from each category were then used to create two comprehensive alternative layouts to the current situation. Alternative two with horizontal aisles with several cross aisles, customized racks, and an ABC classification system was determined to be the best. This alternative improved the efficiency of operations at a minimum implementation cost of $320, which was calculated to be recouped within a maximum of two years.