L4M7 CHAPTER 1

Question 1

A logistics company has a 2-story warehouse in the suburban area. The goods receiving area and dispatch area are located on the ground floor only. There is a lift connecting the two floors. The daily operations of the warehouse are quite busy. Which of the following would be the best arrangement for this warehouse?

Answer 1

Pallets, roller cages and other bulky items will be stored on the ground floor, smaller items in plastic tote boxes will be stored on the first floor.

The purposes of a warehouse is to keep the inventories in good condition and to ensure that the operations are smooth. In the scenario, the warehouse has 2 stories, with goods-in and goods-out areas located on the ground floor and a lift connecting the stories. The lift could become a bottleneck if the goods inside the warehouse are not well-arranged.

Since the lift is often small with limited load capacity, putting heavy bulk items on the first floor will cause bottleneck and increase the chance of accidents. Therefore, palletized items (even if they have low-usage) should be placed on the ground floor. Smaller and lighter items should be stored on the first floor.

Question 2

A supplier delivers large quantities of inventory to its customer’s store, but only charge for the goods as and when they are used. This can be described as…?

Answer 2

Consignment Stock

Consignment stock is stock legally owned by one party, but held by another, meaning that the risk and rewards regarding to the said stock remains with the first party while the second party is responsible for distribution or retail operations. Ownership of consignment stock is passed only when the stock is used (issued or sold in the case of a shop). Unused stock in a warehouse may be returned to the supplier when it concerns standard manufactured products. With customer specific items, agreements concerning returning products, should be negotiated.

Question 3

ANTA Logistics is looking for a place to build a new, integrated cold chain facility, “Chill Hub”, to its customers. Which of the following need to be considered when selecting the location of the new facility?

Answer 3

Accessibility to roads and highways
Availability of the building

There are many different factors that must be considered when assessing warehouse and stock locations:

• Operating cost of the location or area
• Availability and suitability of warehouses
• Availability of manpower or labour
• Proximity to suppliers and customers
• Access to transport infrastructure (domestic and international)
• The political and security environment of the location

Question 4

Bulk loose coal that requires a massive handling system should be stored in which area?

Answer 4

Stockyard

Materials that will not easily deteriorate, are generally stored in open or fairly covered areas (stockyard). The materials are usually in bulk, like steel plates or coils casting, timber coal, steel barrels, cable drums, piping, lampposts, lorries, etc.

Stockyards are open or semi-covered areas that are used for the following:

• Bulk loose or packaged materials
• Bulky or oversized items that may be difficult to move inside
• Materials that may require specialized handling, loading or unloading

Question 5

Can RFID tags work when they are attached to metal surfaces or embedded within metal products?

Answer 5

Yes, some technologies allow RFID tags to work on metal or within metal products

Mounting or embedding RFID tags on metal can be tricky. Metal surfaces reflect energy emitted from RFID readers and create interference for RFID tag antennas, which means the tag isn’t able to receive power and transmit information; however, specific RFID tags will work around metal surfaces. RFID companies have patented technology that allows RFID to work when attached to metal surfaces and even embedded within metal products. As long as you choose the correct RFID equipment for your environment and application, you won’t need to worry about interference from metal.

Question 6

Do all types of warehouses require access to daylight to reduce the cost of electricity?

Answer 6

No, because some types of stock are sensitive to sunlight.

The design of a building should consider the advantages of natural light as this can reduce the cost of artificial lighting and improve the environmental performance of the building. Daylight entering the building can also help reduce heating costs. Unfortunately some stocks react badly to direct sunlight, and some stock reacts badly to extreme temperature or may require a specific temperature for storage. Some stock may require a warmer temperature than the ambient temperature and other stocks may require cooler temperature. For example, fabric and garment are sensitive to direct sunlight as ultraviolet light catalyses a reaction between the water present in all fabrics and atmospheric oxygen to create hydrogen peroxide. This is a bleaching agent which breaks down the chemical bonds that give dyes their colour.

Question 7

International Standard Book Number (ISBN) is a unique international identification system for each product formed or edition of a monographic publication published or produced by a specific publisher. ISBN is an example of…?

Answer 7

Industry standard code.

The International Standard Book Number (ISBN) is a numeric commercial book identifier which is intended to be unique. Publishers purchase ISBNs from an affiliate of the International ISBN Agency. ISBN is standardized by ISO 2108:2017. ISBN is an example of industry standard code as it applies to commercial books around the world.

Check digits are additional numbers or characters added to codes that a computer uses to verify the number is valid. The intention is to reduce the likelihood of mis-keying an item and hitting an alternative live item. More often, a system is devised which a computer can calculate using combination of numbers.

Own product code system: an organization will use its own product code system. This has the advantage that the organization can construct a code that is effective and fits with its software and variety of items covered.

The Harmonized Commodity Description and Coding System, also known as the Harmonized System (HS) of tariff nomenclature is an internationally standardized system of names and numbers to classify traded products. It came into effect in 1988 and has since been developed and maintained by the World Customs Organization (WCO) (formerly the Customs Co-operation Council), an independent intergovernmental organization based in Brussels, Belgium, with over 200 member countries.

Question 8

The practice of unloading goods from inbound delivery vehicles and loading them directly onto outbound vehicles is known as …?

Answer 8

Cross-docking

Cross-docking is the practice of unloading goods from inbound delivery vehicles and loading them directly onto outbound vehicles. By eliminating or minimizing warehouse storage costs, space requirements and inventory handling, cross-docking can streamline supply chains and help them move goods to market faster and more efficiently.

Cross-docking usually takes place in a dedicated docking terminal in a warehouse, where inbound goods are first received at a dock and sorted according to their final destinations. They are then moved to the other side of the dock via forklift, conveyor belt or other equipment and loaded on outbound vehicles.

Cross-docking works best with products that need to be transported quickly, such as food, that have already been sorted and labeled for customers, and do not need quality inspections or have steady demand.

Question 9

The minimal total cost is always achieved when there is only one warehouse. Is this statement true?

Answer 9

No, fewer warehouse may lead to increasing transport costs.

The total cost of storage consists of two different costs:

• The cost of warehouses: each one has a different cost, and each has the cost of stock-holding and stock management included
• The transport costs: the total transport cost reduces as further warehouses mean shorter final delivery to the customers.

Depending on each situation, the optimal number of warehouses varies. Generally, more facilities will increase the cost of warehouses while reduce the transport costs and vice versa.

Question 10

The width of aisles within a warehouse is determined by…?

Answer 10

The turning cycle of the forklift and the size of the pallets.

Start with the basic right-angle stacking width

Add the load length

Add 12 inches for clearance

The basic right-angle stacking width is the smallest amount of space a forklift needs turn in order to insert its forks into a pallet. You can find basic right-angle stack measurements in the equipment manual or by contacting TMHNC if your business is located in Northern California. This measurement does not include the length of the load or room need for clearance.

Load lengths vary depending on your application, products, etc. As a starting point, a standard pallet has a 48-inch load length. Always check your forklift’s data plate for the rated capacity (which is affected by attachments and other factors).
Adding 12 inches for clearance ensures you have enough room for your forklift’s turn radius and helps protect against damage from operator error and/or product that may hang over the edge of the pallet.

Question 11

To improve the security of a warehouse, alarm systems are commonly used. Which of the following is an important part of these systems?

Answer 11

Sensors

The most basic alarm consists of one or more sensors to detect intruders, and an alerting device to indicate the intrusion. However, a typical premises security alarm employs the following components:

Premises control unit (PCU), Alarm Control Panel (ACP), or simply panel: The “brain” of the system, it reads sensor inputs, tracks arm/disarm status, and signals intrusions. In modern system, this is typically one or more computer circuit boards inside a metal enclosure, along with a power supply.

Sensors: Devices which detect intrusions. Sensors may be placed at the perimeter of the protected area, within it, or both. Sensors can detect intruders by a variety of methods, such as monitoring doors and windows for opening, or by monitoring unoccupied interiors for motions, sound, vibration, or other disturbances.

Alerting devices: These indicate an alarm condition. Most commonly, these are bells, sirens, and/or flashing lights. Alerting devices serve the dual purposes of warning occupants of intrusion, and potentially scaring off burglars. These devices may also be used to warn occupants of a fire or smoke condition.

Keypads: Small devices, typically wall-mounted, which function as the human-machine interface to the system. In addition to buttons, keypads typically feature indicator lights, a small multi-character display, or both etc.

Interconnections between components. This may consist of direct wiring to the control unit, or wireless links with local power supplies.

In addition to the system itself, security alarms are often coupled with a monitoring service. In the event of an alarm, the premises control unit contacts a central monitoring station. Operators at the station see the signal and take appropriate action, such as contacting property owners, notifying police, or dispatching private security forces. Such signals may be transmitted via dedicated alarm circuits, telephone lines, or the internet.

Question 12

To make loading/unloading more effective and efficient, which feature should be included in a vehicle dock design?

Answer 12

A dock platform that is almost at the same level as the height of the trailer’s rear platform.

A warehouse dock is a feature of warehouse design - used for unloading and loading vehicles. It is crucial to carefully design where they are externally located in a facility and choose the best type of dock depending on the available space.

In many cases efficient and effective loading and unloading is achieved by a dock design that places the loading and unloading vehicle’ rear platform at the same height as the warehouse floor.

Slopes in docking areas must always be as small as possible: the gentler the slope, the less chance of errors and accidents. If a warehouse is going to be used by large volume vehicles, such as high cubes, it may be necessary to install special devices, such as hydraulically adjustable docks or ground level lift platforms.

Current trends indicate that vehicles that are longer and wider and have a greater volume will be increasingly common. Therefore, when planning the location of the docks, it would be useful to ensure that there is a large area for the approach, maneuvering and build-up of large vehicles.

One option to increase the efficiency of the docks is to combine reception and dispatch into a single area (dual use). This solution drastically reduces costs and, above all, increases the use of handling equipment and personnel. However, if this is justified by the volume of material flows, there can also be separate access points for each function (some for reception and others for dispatch - ‘sole use’).

Question 13

U-shape flow layout can utilize handling equipment if the high demands items are located adjacent to the shipping docks. Is this statement true?

Answer 13

Yes, because this layout places receiving docks and dispatch docks close to one another.

A ‘U’ flow occurs when the goods receipt and dispatch functions are located at the same end of a warehouse building.

Products flow in at receiving, move in to storage in the back of the warehouse, and then to shipping, which is located adjacent to receiving on the same side of the building.

Items with higher throughput level are located closer to the loading bays.

Advantages of ‘U’ Flow

Excellent utilization of dock resources because the receiving and shipping processes can share dock doors

Facilitating cross-docking because the receiving and shipping docks are adjacent to one another and may be co-mingled

Excellent lift truck utilization because put away and retrieval trips are easily combined and because the storage locations closest to the receiving and shipping docks are natural locations to house fast moving items

Yields excellent security because there is a single side of the building used for entry and exit

Question 14

When deciding on the storage facilities and locations, an organization needs to assess the current situation comprehensively and forecast the future demands. Quantitative analysis is the best method for these activities. Is this statement true?

Answer 14

No, some tangible information is difficult to collect and measure.

Decisions regarding stores and warehouse locations involve a complex range of issues that are unique to each business. Most storage facilities and location decisions are based on a combination of qualitative and quantitative analysis.

Qualitative analysis uses subjective judgment to analyze a situation based on non-quantifiable information, such as potential markets for new products, forecast on possible risks that may happen, etc.

Quantitative analysis (QA) is a technique that uses mathematical and statistical modeling, measurement, and research to understand behavior. Quantitative analysts represent a given reality in terms of a numerical value. This may include the following:

Cost analysis for the current premises and future predictions based on current premises

Cost analysis for routine operations

Current inventory performance measures: lead times, service levels, rate of stock turn, stock-outs in a given period and stock cover

To get a big picture of the current situation and future demands, organization should combine both qualitative and quantitative methods so that useful information is achieved and well-informed decisions are made.

Question 15

Which component of an RFID device is responsible for sending and receiving radio waves?

Answer 15

Antenna

RFID tags are made of three different components: an RFID chip, which is an integrated circuit (IC), an antenna, and a substrate. RFID Antennas are necessary elements in an RFID system because they convert the RFID reader’s signal into RF waves that can be picked up by RFID tags. Without some type of RFID antenna, whether integrated or stand-alone, the RFID reader cannot properly send and receive signals to RFID tags.

Question 16

Which of the following allows an organisation to have more flexible space for storage by leveraging the facilities of other parties?

Answer 16

Temporary warehousing and Consignment stocking

Temporary warehousing (or ‘Very short-term warehousing’) is offered in the market where organisation makes their requirements for space open online to offers or bids for available space. This appears to be an emerging market and service providers in the UK and USA typically quote a price per pallet per week with some also requiring a ‘transaction fee’ for movements of each pallet in and out.

Consignment stocking is a facility offered by a supplier to a buyer to allow a delivery of stock to the buyer with payment only after it is used or sold to a customer.

Double-deep pallet racking and carousel-style storage are two tools that leverage space within a warehouse.

Question 17

Which of the following are features of product codes?

Answer 17

Product codes link products’ characteristics
Many internal processes use the product codes as facilitators

The product code is often the key to obtaining documentation relating to products.

Product codes are often use to link internal processes. Some computerized inventory systems trigger alerts when specific items or volumes are ordered - this could be an out-of-stock warning or potential volume errors.

In many cases, an organization will use its own product code system. The organization constructs a code that is effective and fits with its software and the variety of items covered. So these codes may or may not comply with any international standards (such as GS1 specifications, ISO standards, etc.). As organizations make up the code themselves, the codes may look identical to others. For example, SKU414675 reveals that it is used for many items, including the following:

• A UK wholesaler’s six-pack of branded cola
• An Australian snack food
• UK flower seeds
• An Italian desk sold in Japan
• A Brazilian light fitting

Question 18

Which of the following are main objectives of warehouse operations?

Answer 18

To minimize stock loss and deterioration
To ensure stock availability when customers demand

The purposes of stores and warehouses are:

1. Maximum use of space.
2. Ready access to all items.
3. Efficient movement of goods.
4. Effective utilization of labour & equipment’s
5. Maximum protection of items
6. Good-house-keeping.

Question 19

Which of the following are most likely to be direct benefits of applying RFID technology?

Answer 19

Multiple items tracking
Large information capacity

RFID tags are the small devices that can be embedded in labels or attached to tags which work with radio transmitters and/or receivers to identify themselves.

RFID tags can be used to do the following:

• Track individual items
• Track boxes of products, cages of products and pallets
• Track containers with multiple loads
• Locate equipment within a building
• Trigger alarms should equipment or stock be removed without authorization.

RFID devices have a very small integrated circuit incorporating a small memory capability - many are smaller than 2mm square and 2mm thick. Despite its size, many can hold 2000 characters of data.

RFID operating rage depends on the radio frequency used, receiver capability and the environment. Some tags are only readable from under 1m, others can have a 100m range.

RFID tags and labels are very specific to the type of material and size of your assets. For example, metal will deactivate the RFID antenna and the tag will not transmit at all. Using RFID on metal requires a special type of tag with an RFID block to prevent interference with the antenna. Liquid products can also affect the reliability of the RFID signal. To use RFID tags in specific environments, some technologies are needed to support them.

Question 20

Which of the following are most likely to be the purposes of packing and packaging?

Answer 20

Packaging needs to be done for several reasons.
To protect the product
To improve the product recognition

Safety: Packaging is used to keep your product safe from external factors. It also prevents human tampering. If you want to sell fruit juice, you just can’t hand it over to customers. It should be packaged in something, like a stand up pouch.

Brand visibility: You provide the best product in your category and you want your customers to remember that. How else will you do that without using the right kind of creative food packaging?

Bundling it together: If you want to sell an ounce of something, you need to create a packet so that the right amount is bundled together.

Theft prevention: If you sell your product loose, there are chances that the retailer doesn’t give the right amount to the customer and saves some part for himself. There are other cases too where theft can be done in the absence of packaging.

Question 21

Which of the following are typical characteristics of 2D barcodes?

Answer 21

2D barcodes are machine readable
2D barcodes can contain more data than 1D barcodes

Two-dimensional (2D) barcodes look like squares or rectangles that contain many small, individual dots. This has many different types (i.e. Data matrix, QR codes, Aztec code,…) and several different standards in use (i.e. GS1 standards, ISO/IEC 18004:2015). It can be substituted for 1D barcode, but it has the capability to hold a larger amount of data. For examples, GS1 Data Matrix can contain 3116 Numeric characters or 2335 Alphanumeric characters while GS1-128 barcode has maximum capacity of 48 characters.

Like 1D barcodes, 2D barcodes are also machine-readable with dots/squares and spaces.

Since the code is two dimensional, conventional laser scanner can’t read it. 2D barcodes require imaging scanner to read.

2D barcodes can be also used for different purposes throughout the supply chain: identifying products/SKU (single unit, packaged or pallet), identifying content of a purchase order or delivery, identifying the batch number from which the item originates, identifying the manufacturer, country of origin etc, tracking status of an order, shipment or delivery

Question 22

Which of the following are warehouse layouts that allow the cross aisle to meet picking aisle at angles different from 90 degrees?

Answer 22

‘Fan’ shaped layout.
Kevin R. Gue and Russell D. Meller proposed alternative aisle designs:
- The ‘Fan’ shaped layout (or “Flying V”). This layout maintains parallel picking aisles, but allows the cross aisle to take on a different shape. If travel begins and ends at the bottom of the V, Gue and Meller expected distance to retrieve a single pallet is 10% less in this warehouse than in an equivalent traditional design.

Herringbone-shaped layout
- The Herringbone-shaped layout (or commonly referred as Fishbone layout) combines the vertical picking rows of a traditional warehouse with a second set of horizontal picking rows, divided by a V-shaped diagonal alley crossing the entire warehouse. This simple modification to the typical warehouse design allows employees (e.g. a forklift driver) to increase travel speed between picking locations. Efficiency gains achieved through a layout reconfiguration would reduce picking cost up to 23% compared to an equivalent warehouse using a traditional configuration.

Question 23

Which of the following code systems is commonly used by governments as a basis for their Customs tariffs and for the collection of international trade statistics?

Answer 23

The Harmonized Commodity Description and Coding System

The Harmonized Commodity Description and Coding System, also known as the Harmonized System (HS) of tariff nomenclature is an internationally standardized system of names and numbers to classify traded products. It came into effect in 1988 and has since been developed and maintained by the World Customs Organization (WCO) (formerly the Customs Co-operation Council), an independent intergovernmental organization based in Brussels, Belgium, with over 200 member countries.

The Global Trade Item Number (GTIN) is an identifier for trade items, developed by GS1. Such identifiers are used to look up product information in a database (often by entering the number through a barcode scanner pointed at an actual product) which may belong to a retailer, manufacturer, collector, researcher, or other entity.

The Global Location Number can be used by companies to identify their locations, giving them complete flexibility to identify any type or level of location required.

The International Mobile Equipment Identity (IMEI) is a number, usually unique, to identify 3GPP and iDEN mobile phones, as well as some satellite phones.

Question 24

Which of the following is often created by each business and commonly used for the purpose of inventory management?

Answer 24

SKU - Stock keeping unit.

Organizations often create their own stock keeping unit (SKU) numbering system, which may or may not have a meaningful structure. Stock keeping unit is a number that is assigned to a product for the purpose of inventory management and its tracking. In other words, a stock keeping unit is a unique identifier assigned to each product for easier and more efficient record keeping.

An FDA (US Food and Drug Administration) product code describes a specific product and contains a combination of five to seven numbers and letters. The product code submitted with each FDA line item should match the actual product name and/or invoice description of the product.

The International Standard Book Number is a numeric commercial book identifier which is intended to be unique. Publishers purchase ISBNs from an affiliate of the International ISBN Agency.

The Harmonized Commodity Description and Coding System, also known as the Harmonized System (HS) of tariff nomenclature is an internationally standardized system of names and numbers to classify traded products.

Question 25

Which of the following is the character that allows the computer to verify whether a product code is entered correctly?

Answer 25

Check Digits.

Many codes have integrated check digits. These are additional numbers or characters added to codes that a computer uses to verify the number is valid. The intention is to reduce the likelihood of miskeying an item and hitting an alternative live item. More often, a system is devised which a computer can calculate using combination of numbers.

Barcode is a graphic symbol used to convey data. Typically the characters in a barcode symbol consist of bars/space pattern. Barcode is the method of representing data in a visual, machine-readable form. Initially barcodes represented data by varying the width and spacing of parallel lines.

Radio-frequency identification (RFID) uses electromagnetic fields to automatically identify and track tags attached to objects.

A prefix is an affix which is placed before the stem of a word or a string. A product code may have prefix which indicates its group, country, origins, etc.

Question 26

Which of the following is the cylindrical container that is suitable for liquids or loose material?

Answer 26

A Drum
A Drum is the container for stock, which is usually cylindrical and can be made from a variety of materials. Contents are usually loose material or liquids.

Tote box is the reusable storage box. These can be open or have lids or flaps to close them and come in a large variety of sizes and weight loadings. A tote is ideal for holding and hauling items such as: tools, fasteners, bark dust, dry cement, cords, wires, smaller boxes,…

For larger and bulkier items, industrial containers make it easy to keep things stored and in one spot for transportation. Due to the metal interior, an industrial container is more appropriate for items that — unlike tools and small pieces of machinery — lack any surface sensitivity.

Solid containers like bins and totes are far from the only storage devices for the various materials that are needed in abundance at factories and warehouses. Another option is the storage bag, which can be used to hold bulk supplies of items until they’re needed for the department shelves or assembly lines.

Question 27

Which of the following is the most suitable container of fasteners (screws, nails, nuts and bolts,…)?

Answer 27

Tote box

Tote box is the reusable storage box. These can be open or have lids or flaps to close them and come in a large variety of sizes and weight loadings. A tote is ideal for holding and hauling items such as: tools, fasteners, bark dust, dry cement, cords, wires, smaller boxes,…

Pallets are the platform structures designed to support a load and be lifted using the forks (typically seen on forklift trucks and other equipment). These are in a variety of standard sizes and can be made of many materials including plastics, resin, board or timber. Pallets are not containers, but support platforms.

Bar racks are designed to store bars and pipes.

Stock cages are available in many sizes and can hold single items or groups of items

Question 28

Which of the following statements about radio frequency identification (RFID) is NOT true?

Answer 28

RFID systems transmit radio signals over extreme long distances

RFID tags have very limited range.
RFID tags can be used to do the following:

• Track individual items
• Track boxes of products, cages of products and pallet
• Track containers with multiple loads
• Locate equipment within a building
• Trigger alarms should equipment or stock be removed without authorization.

RFID tags are made of three different components: an RFID chip, which is an integrated circuit (IC), an antenna, and a substrate. RFID chips are very small integrated circuit incorporating a small memory capability - many are smaller than 2mm square and 2mm thick. Despite its size, many can hold 2000 characters of data. Many retailers simply use the tag as a thick label and print both sides with product information and perhaps a barcode.

It is important to note that there are multiple standards in use for RFID - some of these are standardized for industries but there are also national standards in operations. These standards need to be investigated before investment as not all readers work with all cards. GS1 is a non-for-profit organization which make the standards for barcodes and RFID.

Question 29

Which one of the following statements is true about radio frequency identification (RFID)?

Answer 29

Normally passive RFID tags store ID numbers

Radio frequency identification (RFID) are items which use radio technology to identify itself and its location subject to having appropriate hardware and software.

RFID tags are made of three different components: an RFID chip, which is an integrated circuit (IC), an antenna, and a substrate.

A RFID Reader is a device that uses radio-frequency waves to wirelessly transfer data between itself and a RFID tag/label in order to identify, categorize and track assets. When combined with the right RFID software, a RFID reader can identify objects quicker, more accurately, at a reduced overall cost, and at various points of the object’s lifecycle.

Passive RFID systems use tags with no internal power source and instead are powered by the electromagnetic energy transmitted from an RFID reader. Passive RFID tags are used for applications such as access control, file tracking, race timing, supply chain management, smart labels, and more.

Active RFID systems have three essential parts – a reader or interrogator, antenna, and a tag. Active RFID tags possess their own power source – an internal battery that enables them to have extremely long read ranges as well as large memory banks.

Question 30

Which type of codes can a barcode laser scanner (linear scanner) read?

Answer 30

1D barcode

One-dimensional (or 1D) barcodes systematically represent data by varying the widths and spacings of parallel lines. These include some of the most traditional and well-recognized barcode types, such as the UPC and EAN codes. 1D barcodes are also commonly referred to as linear barcodes.

Two-dimensional (2D) barcodes look like squares or rectangles that contain many small, individual dots. QR codes, Data matrix and Aztec codes are examples of 2D barcodes

Numerical code contains all numbers, no letters

There are two different scan engine types (laser scanner versus imager) for interpreting the information provided in the barcode. Many companies producing the technology capable of reading the barcode data use the term “scanning” regardless of the type of scan engine used.

Linear (1D) codes can be scanned with a traditional laser scanner. A laser scan engine uses a laser and mirror to create the bar that scans the information. 1D barcode scanners will only interpret the linear barcode scanning technology. 1D barcode scanners are typically less expensive since the type of encryptions they can decode is limited.

Question 31

XYZ Ltd is a retailer in the US. Their customers’ demand for Thanksgiving and Christmas decorations usually rises in the end of the year. This irregular demand results in more required storage space for finished goods during peak seasons. Which of the following are possible solutions for dealing with required additional space?

Answer 31

Maximizing flexibility in warehouse layout
Installing mezzanine floor

Possible solutions to the high irregular or seasonal demand problems are listed below:

• Take advantage of the height of the warehouse
- Mezzanine floor
- High racking system (increase storage capacity but require high-reach material handling equipment)
• Eliminate dead stock or inventory
• Improve material flow
• Improve storage location method
• Consider using aisle space during demand peak
• Narrow aisles between racks (require narrow handling equipment)
• Carousel-type storage system
• Auto-storage and retrievals system (ASRS)

Question 32

Which of the following is the minimum aisle width for using standard counterbalanced forklifts?

Answer 32

10.5 to 13.1 feet

Minimum open aisle width for standard counterbalance forklift is 10.5-13.1 ft.

Question 33

Which of the following refer to material used for filling the void left in the box but they have poor environmental profile?

Answer 33

Polystyrene

Void filling is the general term giving to the challenge of filling the space left in a box after the products have been packed. This means that if there is no void filling material, the product inside can move around and could be damaged. Materials to fill voids to secure contents

• Polystyrene (PS) is a synthetic aromatic hydrocarbon polymer made from the monomer known as styrene. Polystyrene can be solid or foamed. General-purpose polystyrene is clear, hard, and rather brittle. It is an inexpensive resin per unit weight. It is a rather poor barrier to oxygen and water vapour and has a relatively low melting point. Polystyrene is one of the most widely used plastics, the scale of its production being several million tonnes per year. Polystyrene can be naturally transparent, but can be coloured with colourants. Uses include protective packaging (such as packing peanuts and CD and DVD cases), containers, lids, bottles, trays, tumblers, disposable cutlery and in the making of models. Polystyrene is generally considered to be non-biodegradable. However, certain organisms are able to degrade it, albeit very slowly.
Chips made of bio-degradable materials

• Absorbent and fire-resistant material
• Shredded paper, cardboard or wood-Based material
• Paper or cardboard rolls
• Bubble wrap
• Air-filled cushions
• Self expanding foam

Straps are used to group items into unit load. Polypropylene or polyester are the materials most often used. The wider the strap, the stronger it will be. Using more than one strap and straps for length and width will create a strong place for stock.

Question 34

Which of the following is the material handling equipment which uses the suction force to lift an item?

Answer 34

VACUUM LIFTER uses the vacuum pad which attaches itself to a product. The suction force allows the product to be lifted (and rotated and placed). Vacuum lifters are used for moving and positioning glass sheets, but are also seen lifting boxes, plastic sacks, sheets of building materials and pipework. Some models feature hydraulic arms which allow easy movement of the lifted load. The lifting system will have a number of sucker pads and vacuum capability which determines the maximum weights and largest items that can be lifted.

DOLLY consists of stack and sets of wheels (either casters or rollers) under the stack that allow the dolly and the heavy object on top of it to move easily and smoothly. For moving in a straight line, rollers is ideal. If you want to move manoeuvrability, dolly with sets of casters will let you swivel and turn.

SACK TRUCK (hand truck) is an L-shaped box-moving handcart. It comprises a small base platform with two wheels at the base and a larger vertical structure. A small ledge to set objects on flat against the floor when the sack truck is upright. When moving, the truck and object are then tilted backward based on the vertical structure until the weight is balanced over the large wheels, making otherwise bulky and heavy objects easier to move.

PALLET STACKER is designed to lift and stack pallets. This one is fully mobile so can move easily around the warehouse. An operator would typically sit or stand while driving like a counterbalanced, reach or straddle lift truck.

Question 35

A manager who is concerned about the environmental impact of packaging should do which of the following?

Answer 35

Adopt international environmental packaging standards’.

In principle, use of any materials involves an environmental cost. Some packaging materials use a lot of natural resources and energy to produce. The journey taken by packaging from raw material to manufacturing and then to the initial user also incurs a ‘carbon footprint’. The weight of packaging contributes to the fuel usage of vehicles while the volume used can add up to additional journeys or the use of larger vehicles. Finally, the reuse, return, disposal or recycling will also involve additional to the environmental cost.

In this question:

• ‘Purchase the packaging materials in bulk’ may incur additional fuel and carbon footprint in delivering these materials
• ‘Try to reduce the costs of packaging’ may prompt the organisation to use less eco-friendly and cheap materials like polystyrene chips
• ‘Not use the packaging materials at all’ can increase the environmental performance of packaging activities, but it also harms the products to be delivered and may cause other environmental problems (i.e. spillage of toxic chemicals into the environment)

So the correct answer should be: ‘Adopt international environmental packaging standards’. The International Standards Organisation (ISO) has published several standards regarding packaging and environment, namely ISO 18601, ISO 18602, ISO 18603, ISO 18604, ISO 18605, ISO 18606.

Question 36

Which of the following allow the operators to access higher levels in warehouse facility?

Answer 36

Scissor platforms
Order picker

It is important to ensure safe working in storage facilities, and access to higher shelves or racking presents a challenge. Lifting at full reach becomes a problem at relative low weight. There can also be danger for other workers who are around someone working at height, from the movement of equipment or dropping stock from a height.

Scissor platforms are used in high-roof warehouses to gain access to lighting, high-racking units and sections of wall and roof.

Order picker is manual or powered device - some with ride-on capability and some without. This allow for low-level, medium-level and high-level picking of various items. Many are equipped with forks to allow transfer capability of larger picked boxes. Higher-level and narrow or very narrow -aisle versions have the ability to elevate operators on the front platform to higher racking to pick items.

Grabs are designed to hold stock either width-wise or from above. These are either specific devices designed for grabbing materials or are available as an accessory to forklift trucks.

Carousels are space-efficient, rotating devices which allow access to a large range of product from a single location. Designs are variable, with carousels rotating horizontally or vertically until the required items can be retrieved.

Stacker-cranes are designed for the automated storage and retrieval of unit loads, in high-bay warehouses. They travel in aisles equipped with guide rails, electrical supply, data transmission and control systems. To ensure the storage and retrieval functions, the stacker-crane carries out three types of movement : long-travel, lifting and picking.

Question 37

A group of items which are stacked together for more convenient movement is called…?

Answer 37

Unit Load

Unit load is a term used to describe grouping of different items into a convenient stack or stacks which make them easy to handle and store. Typically this involves pallets and/or the plastic wrapping of a load.

Stacker is designed to lift and stack pallets. This one is fully mobile so can move easily around the warehouse. An operator would typically sit or stand while driving like a counterbalanced, reach or straddle lift truck.

A load cell is a type of transducer, specifically a force transducer. It converts a force such as tension, compression, pressure, or torque into an electrical signal that can be measured and standardized.

Unit price is the price of a single product or service, used for example when buying several things together to refer to the price of each one.

Question 38

The optimum balance in the standard ISO 18602:2013 (Packaging and the environment — Optimization of the packaging system) considers which of the following factors?

Answer 38

Environmental impact of losses due to lack of packaging
The process for packaging design, including material selection
Procedures and requirements for packaging that are suitable for organic recycling
Environmental impact of excess packaging

ISO 18602:2013 is about Packaging and the environment — Optimization of the packaging system. ISO 18602:2013 specifies requirements and a procedure for assessment of packaging to ensure that the weight or volume of its material content is optimized consistent with the functions of packaging. This is one of several options for reducing the impact of packaging on the environment.

It also provides methodologies and procedures for

• determining the amount and minimization of substances or mixtures hazardous to the environment, and
• determining the amount of four heavy metals (lead, cadmium, mercury, hexavalent chromium) in packaging.

The optimum balance in this standard weighs the environmental impact of losses that may happen with no packaging or inadequate packaging against the environmental impact from excess packaging.

The process for packaging design, including material selection, is not part of ISO 18602:2013.

The procedure for applying ISO 18602:2013 is contained in ISO 18601.

Question 39

Which of the following are most likely the benefits of using unit loads?

Answer 39

Safer Handling
Reduce handling cost of one unit

The concept of a unit load is to create a stable and secure, easy-to-move group of stock that is fast to load and unload from vehicles.

The advantages of unit load concepts are as the following:

• More items can be handled at the same time, thereby reducing the number of trips required and, potentially, reducing handling costs, loading and unloading times, and product damage.
• Enables the use of standardized material handling equipment.

Question 40

Which of the following can replace pallets as bases for unit loads but they require push pull accessories to retrieve or discharge unit load?

Answer 40

The system of slip sheet load handling involves the use of a thin sheet of material, the slip sheet, as a base on which items are assembled as a unit load for handling, storage, and transport. The slip sheet is used in conjunction with a pallet, if desired, at certain stages in the distribution cycle. If all lift trucks in the cycle are equipped with the proper attachment, an appropriate slip sheet is the only material handling base required. Slip sheet requires special push pull accessories and usually use thin and wide forks.

Skids are generally described as single-deck pallets and do not have bottom flatted layer which makes them less bulky and cheaper than conventional pallets but also less universal in their use.

Shrink wrap, also referred to as shrink film or shrink wrap, is a versatile polymer material used for the packaging of finished goods. Heat is applied to the film – by either a conveyor heat tunnel or an electric or gas heat gun – which catalyzes the film to shrink tightly around the item placed within. This process results in a clear, durable barrier of protection around the product.

Post pallets have a simple metal structure with four uprights and substantial feet to take the load. These may be free standing, but many are designed for the feet to interlock with the posts of another post pallet so that the stack can be created.