planning principles for designing storage areas. · planning principles for designing storage...

PLANNING PRINCIPLES FOR DESIGNING STORAGE AREAS. FOR DEALERSHIPS. NOT FOR SUBSIDIARY AND CENTRAL WAREHOUSES LIKE DMDC.

Guidelines for building owners, warehouse planners, architects, building systems

planners and statics engineers.

Editor:

BMW AG, BV-74

Building and facility consulting

Warehouse planning

July 2012 version 1.1

Author:

Jens Vorwerk

Phone: +49/89/382-41580

Fax: +49/89/382-7041580

E-mail: [email protected]

mailto:[email protected]

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Table of contents

Table of contents ................................................................................................................................. 2

List of graphics .................................................................................................................................... 5

List of figures ...................................................................................................................................... 6

Glossary .............................................................................................................................................. 7

Explanations of symbols ...................................................................................................................... 9

1 Introduction .............................................................................................................................. 10

1.1 Preface, planning principles .............................................................................................. 10

1.2 Introductory information regarding the warehouse ............................................................ 11

2 Requirements of the warehouse ................................................................................................. 12

2.1 Warehouse size ................................................................................................................. 13

2.2 Energy supply ................................................................................................................... 14

2.3 Room heights ................................................................................................................... 14

2.4 Floor composition ............................................................................................................. 16

2.4.1 Floor load capacity in a single-level rack system ..................................................... 16

2.4.2 Floor load capacity in a multi-level rack system ...................................................... 16

2.5 Warehouse lighting........................................................................................................... 17

2.6 Access ways/doors/gates .................................................................................................. 17

2.7 Storage temperature ......................................................................................................... 17

2.7.1 Storage temperature for tyres (unmounted) ........................................................... 17

2.7.2 Temperature for fluids, etc. ..................................................................................... 17

2.7.3 Storage of complete wheels .................................................................................... 18

2.8 Sprinkler system ............................................................................................................... 18

2.8.1 Sprinkler system for spare parts ............................................................................. 18

2.8.2 Tyre storage ............................................................................................................ 18

2.8.3 Complete wheel storage .......................................................................................... 18

2.9 Other equipment in the spare parts warehouse .................................................................. 19

3 Working procedure of warehouse planning ................................................................................ 20

3.1 Basics ............................................................................................................................... 20

3.2 Received documents ......................................................................................................... 21

3.3 Documents returned from BV-74 ...................................................................................... 21

3.4 Warehouse arrangement ................................................................................................... 22

3.4.1 Possibilities for warehouse arrangement ................................................................ 23

- Warehouse 100 m² ........................................................................................................ 23

- Warehouse 200 m² ........................................................................................................ 23

3.4.2 Goods incoming, handover area, night-time delivery ............................................. 24

3.4.3 Floor storage ........................................................................................................... 24

3.4.4 Goods issue ............................................................................................................. 24

3.4.5 Corridors/passageways ........................................................................................... 25

3.4.6 Stairs ....................................................................................................................... 25

3.4.7 Wall distance .......................................................................................................... 25

3.4.8 Storage location ...................................................................................................... 26

3.4.9 Delivery and installation preconditions .................................................................. 27

3.5 Site measurements ............................................................................................................ 27

3.6 Platforms for multi-level systems ...................................................................................... 28

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4 BMW rack types for dealerships ................................................................................................ 29

4.1 Rack designation .............................................................................................................. 30

4.2 BMW shelf rack types ....................................................................................................... 31

4.2.1 BMW rack type 4F .................................................................................................. 31

4.2.2 BMW shelf rack type 4H ......................................................................................... 32

4.2.3 BMW shelf rack type 4J ........................................................................................... 33

4.2.4 BMW shelf rack type 4M ......................................................................................... 34

4.2.5 BMW shelf rack type 4O ......................................................................................... 35

4.2.6 BMW shelf rack type 4V ......................................................................................... 36

4.2.7 BMW rack / rack 4V1 ............................................................................................. 37

4.2.8 BMW shelf rack type 4Y .......................................................................................... 38

4.2.9 BMW shelf rack type 6F .......................................................................................... 39




4.2.13 BMW shelf rack type 6T .......................................................................................... 43

4.2.14 BMW shelf rack type 6T1 ........................................................................................ 44



4.2.17 BMW shelf rack type 6W ........................................................................................ 47

4.2.18 BMW shelf rack type 6X .......................................................................................... 48

4.2.19 BMW shelf rack type 6X1 ........................................................................................ 49



4.2.22 BMW shelf rack type 6Y .......................................................................................... 52

4.2.23 BMW shelf rack type 8F .......................................................................................... 53




4.2.27 BMW shelf rack type 8N ......................................................................................... 57

4.3 BMW special rack types .................................................................................................... 58

4.3.1 BMW special rack type MP ..................................................................................... 58

4.3.2 BMW special rack type R2_10 ................................................................................ 59



4.3.5 BMW special rack type S2_10 ................................................................................. 62

4.3.6 BMW special rack type W2_10 ............................................................................... 63

4.3.7 BMW special rack type W3_10 ............................................................................... 64

4.3.8 BMW special rack type Z1_03 ................................................................................. 65

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5 Sliding carriages ........................................................................................................................ 66

6 Wheel storage ........................................................................................................................... 67

6.1 Possibilities for wheel storage ........................................................................................... 67

6.1.1 Single-depth storage ............................................................................................... 67

6.1.2 Double-depth storage .............................................................................................. 68

6.1.3 Four-deep storage ................................................................................................... 69

6.1.4 Mobile storage using sliding rack............................................................................ 70

7 Storage of parts in general ......................................................................................................... 71

8 Annexes .................................................................................................................................... 72

8.1 Attachment 1 Extract from the Mounting/Demounting Instructions by the wdk dated 22

October 2007. ............................................................................................................................... 72

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List of graphics

Diagram 1: Explanation of symbols German ...................................................................................... 9

Diagram 2: Explanation of symbols English ........................................................................................ 9

Diagram 3: 3D view of a BMW rack type .......................................................................................... 12

Diagram 4: Warehouse size with regard to the number of jobs (values based on experience) .......... 13

Diagram 5: Section through warehouse and workshop in order to show the clear height ................ 14

Diagram 6: Arrangement of the warehouse in the building .............................................................. 22

Diagram 7: Warehouse layout ........................................................................................................... 26

Diagram 8: BMW rack type 4F .......................................................................................................... 31

Diagram 9: BMW rack type 4H ......................................................................................................... 32

Diagram 10: BMW rack type 4J ......................................................................................................... 33

Diagram 11: BMW rack type 4M ....................................................................................................... 34

Diagram 12: BMW rack type 4O ....................................................................................................... 35

Diagram 14: BMW rack type 4V ....................................................................................................... 36

Diagram 15: BMW rack type 4Y ........................................................................................................ 38

Diagram 16: BMW rack type 6F ........................................................................................................ 39

Diagram 17: BMW rack type 6H ....................................................................................................... 40



Diagram 20: BMW rack type 6T ........................................................................................................ 43

Diagram 21: BMW rack type 6T1 ...................................................................................................... 44



Diagram 24: BMW rack type 6W ...................................................................................................... 47

Diagram 25: BMW rack type 6X ........................................................................................................ 48

Diagram 26: BMW rack type 6X2 ...................................................................................................... 50

Diagram 27: BMW rack type 6X3 ...................................................................................................... 51

Diagram 28: BMW rack type 6Y ........................................................................................................ 52

Diagram 29: BMW rack type 8F ........................................................................................................ 53

Diagram 30: BMW rack type 8H ....................................................................................................... 54



Diagram 33: BMW rack type 8N ....................................................................................................... 57

Diagram 34: BMW rack type MP ...................................................................................................... 58

Diagram 35: BMW rack type R2_10 .................................................................................................. 59



Diagram 38: BMW rack type S2_10 .................................................................................................. 62

Diagram 40: BMW rack type W2_10 ................................................................................................. 63

Diagram 41: BMW rack type W3_10 ................................................................................................. 64

Diagram 42: BMW rack type Z1_03 .................................................................................................. 65

Diagram 42: Wheel store with single depth ...................................................................................... 67

Diagram 43: Wheel store with double depth ..................................................................................... 68

Diagram 42: Four-deep wheel store .................................................................................................. 69

Diagram 45: Mobile wheel store ....................................................................................................... 70

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List of figures

Figure 1: BMW rack type 6X1 .......................................................... Fehler! Textmarke nicht definiert.

Figure 2: Racks on sliding carriage.................................................................................................... 66

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Glossary

A

Outstanding amount Number of parts items ordered that are not yet held in the

warehouse

B

Platform (self-supporting or fixed) Mesh pedestal in multi-level rack system

C

Celsius (C) Unit of measurement for temperature

D

DIN Deutsches Institut für Normung (German Standardisation

Institute)

DN

DMDC

Nominal diameter

Dealer Metro Distribution Centre

E

EN European standard

F

Feet (ft) Unit of length, one foot is equivalent to 30.48 cm

G

H

Hertz (Hz) Physical unit for frequency

I

IT Information Technology

K

Kilopond (kp) Unit of weight (1 kp = 9.80655 N)

Kilowatt (kW) Unit of power

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L

LAN Local Area Network

Lead time Time interval between order and admission into

warehouse

lux Unit of illumination intensity

N

O

P

PC Personal Computer

Pick Access to storage bin

PVC Polyvinyl chloride for floor coverings

R

Reach Duration of expected availability of the current stock of

each position

S

Sectional door Door with rotating sections

V

Volt (V) Unit of electrical voltage

W

wdk Wirtschaftsverband der deutschen Kautschukindustrie e.

V.

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Explanations of symbols

Diagram 1: Explanation of symbols German

Diagram 2: Explanation of symbols English

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1 Introduction

1.1 Preface, planning principles

The investment in the service area of a dealership or service company represents a significant portion of

the overall investment. In new buildings or conversions, planning errors can result in long-lasting

restrictions in service performance and customer satisfaction. This can be due to an inadequate

interplay between the service processes, the warehouse facility and the warehouse layout for the hall

floor, walls and ceiling. The tasks of warehouse planning are to avoid such occurrences, and to create

optimum conditions.

This document explains principles about the planning of warehouse areas for stocking spare parts in

BMW Group Service. All aspects of the design of a warehouse in accordance with requirements are

described systematically and in detail. All usual functional units are represented with regard to their

arrangement, size, technical equipment and interfaces to the building. The design of warehouse areas is

based on BMW Group spare parts.

This warehouse planning handbook makes it possible for building owners, warehouse planners,

architects, building systems planners and statics engineers to profit from the experience of BMW

Service warehouse planning right from the start. It is possible to call on details or design entire

functional units in accordance with requirements. Consistent use of these planning principles will make

an important contribution to the smooth interplay between BMW Group vehicle and service technology

in everyday workshop practice. Last but not least, the planning-side health, safety and ergonomic

aspects represent an important building block for achieving high levels of motivation and performance

in service employees.

These planning principles do not deal with the special aspects of individual countries (e.g. climate,

building codes, official guidelines, safety requirements). The local planners must take account of

deviations arising in this regard.

The dimension of the warehouse areas mentioned below relate to a service company (not branches and

large warehouses) of the BMW Group, and should therefore be regarded in all cases as minimum

requirements.

All data and dimensions contained in the warehouse planning manual are up to date and valid at the

time of publication.

BV-74 can assist you during each planning phase of new planning or restructuring projects for your

warehouse.

The warehouse planning manual is subject to continuous further development. The current version

applies.

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1.2 Introductory information regarding the warehouse

The pure material costs for warehouse equipment (without suspended ceiling) can be estimated as

approx. €7.50 per parts item to be stored.

With regard to the warehouse area, this results in an estimated amount of €250 – 300 per square metre.

Thus, 5,500 items in an area of 170 square meters would cost about €50,000.

The fire load should be kept as low as possible in order to avoid the need for a sprinkler system.

Utilisation of the storage area is a decisive factor with regard to the number of items that can be stored.

On average, only about 3-5% of the warehouse area is actually used by spare parts. The remaining area

is made up of corridors, air in the racks and special functions, although we strive to utilise the

warehouse area more efficiently.

In areas prone to earthquakes, it is recommended for the warehouse facility to be subjected to a special

study. Under certain circumstances, it may be necessary to increase the number of cross braces, and to

secure the BMW rack types separately to prevent tipping over.

It may be the case that public authorities require an auditable statics report for rack system, which must

be considered in advance.

In all cases, the parts must be put into the warehouse in such a way that

1. Inwards and outwards movements do not give rise to any damage.

2. No part is damaged in any way due to the nature of the storage.

3. All parts can be clearly located by means of an appropriate and quickly understandable logical

system.

4. The necessary pathways, processes and forms of organisation are optimally aligned to the

requirements of those involved.

The question of disposing of spare parts with extremely low or no turnover should be considered. The

reason is that these parts take up valuable space by occupying a storage bin, but do not generate

turnover.

Such parts can quickly occupy relatively large areas in the spare parts warehouse, thereby preventing

important product expansions.

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2 Requirements of the warehouse

This chapter explains the general requirements that are to be regarded as the minimum requirements

for a warehouse in accordance with BMW guidelines, in order to allow the defined BMW rack types to

be integrated.

A self-supporting mezzanine floor allows the BMW racks to be arranged as required and independently

on all levels, and is therefore more flexible and to be recommended, including with regard to future

modifications. Racks that have an intermediate level can no longer be changed in their position

subsequently, or else it is only possible to remove or exchange such racks with considerable complexity.

Consideration should also be given to the possibility of implementing a future expansion. 15 - 25 % of

the warehouse area should be additional functional area.

In order to allow all storage bins to be recorded electronically in all systems used at BMW companies,

we are currently planning to use only racks with a maximum of 9 storage levels.

The BMW rack types have been defined at a height of 2.30 m (approx. 7.54 ft). This means that the

uppermost shelf is attached at a height of about 2.00 m (approx. 6.56 ft) (suspended), thereby allowing

the items to be reached without requiring assistance.

Annual inspection requirement for warehouse facilities.

European standard DIN EN 15635

Standard EN15635 Steel static storage systems - application and maintenance of storage equipment,

was published on 1 August 2009. In conjunction with the regulation for industrial safety (Bearish), DIN

EN 15635 regulates the scope and procedure of checks on warehouse facilities. The warehouse owner is

responsible for providing safe operating conditions, therefore the owner bears responsibility for the

employees, the warehouse facility and the integrity of its goods

Diagram 3: 3D view of a BMW rack type

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2.1 Warehouse size

We recommend 100 m² as the absolute minimum area for a spare parts warehouse. The spare parts

warehouse should not include storage for office documents, brochures, customer parts (roof racks,

hardtops, wheels), used parts, warranty parts, etc.

Allow 0.5m² per wheel set for storing complete car wheels. In this case, it is a condition that the room

height must be at least 2.5 m (approx. 8.2 ft), and that a rectangular warehouse area is available with a

ratio between the side lengths of approx. 2:3. The amount of space required per wheel set increases if

the conditions in the room are less favourable.

Warehouse sizes in excess of 500m² are unusual, and only make sense in special cases.

The shape of the floor plan is decisive with regard to effective use; ideally it should be rectangular with

a ratio between the side lengths of 2:1 to 3:4. Rooms with a high side length ratio (long, narrow rooms)

result in unfavourable utilisation of space and should be avoided.

BV-74 can calculate a precise warehouse size on presentation of a data set detailing the items to be

stored, together with quantity specifications.

This calculation is based on the dealer master stock with quantity specifications, BMW rack types and

delivery frequency of at least once a week.

Possible reduction in area.

Higher racks (2.5m / approx. 8.2 ft), sliding carriages, multi-level systems, higher delivery frequencies

and a reduction in the parts stock or parts quantities.

Diagram 4: Warehouse size with regard to the number of jobs (values based on experience)

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2.2 Energy supply

It is recommended that socket outlets and network sockets (CAT 6) should be provided at suitable

points in order to allow VDU workstations to be set up with PC and IT-based warehouse management

via LAN.

2.3 Room heights

In all cases, the room height is subject to the requirements of accident prevention regulations by the

employers' professional liability insurers.

If using racks with a structural height of 2.30 m (approx. 7.55 ft), it is necessary to have a clear room

height of 2.40 m (approx. 7.87 ft) for each rack level.

Using a sliding carriage increases the necessary minimum room height by 15 cm to 2.55m (approx.

8.37ft) per rack level. Alternatively, the rack uprights can be made shorter, although this leads to a

reduction in volume with all the associated disadvantages.

This clear room height is required over the entire sliding area

Diagram 5: Section through warehouse and workshop in order to show the clear height

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Diagram ..: Complete wheel storage

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2.4 Floor composition

The floor load capacity is implemented in BMW building standards, and takes account of all conditions

that occur during storage and transport of spare parts within the warehouse.

The minimum requirement on the floor covering in the spare parts warehouse results from the load

capacity and the surface quality.

The surface quality should correspond to industrial screed, and the composition must withstand the

minimum requirements on the floor load capacity (see chapters 3.5.1 and 3.5.2). Alternatively, the floor

covering can comprise bricks, steel mesh or the like.

Do not use magnetite screed, because this reacts chemically with the galvanised support frames of

BMW rack types, leading to rust formation. It is then necessary to use bases in order to counteract this

effect.

Using a sliding carriage does not impose any additional requirements on the floor. No sliding rails are

required either.

2.4.1 Floor load capacity in a single-level rack system

The floor load capacity in a single-level rack system corresponds to the general floor load capacity, and

is specified as 10 kN/square metre.

2.4.2 Floor load capacity in a multi-level rack system

The floor load capacity of a double-level rack system is important above all in the design of the self-

supporting platform. In order to allow transport trolleys to be driven over the steel mesh panels without

restrictions, we recommend a mesh width of 44 x 10 mm (approx. 0.11 x 0.03 ft). The steel mesh

manufacturer must implement the floor load capacity accordingly. Alternatively, compressed

particleboards can be used for the mezzanine floor. A combination of compressed particleboards in the

main corridors and steel mesh panels in the aisles is possible in order to reduce costs.

The floor load capacity of multi-level rack systems depends on the quantity of items that are required to

be admitted into warehouse.

Thus, the recommended floor load capacity with standard storage is15 kN/m².

Min. 25 kN/m² is required if pallets will be stored in racks or if forklift trucks will be used in the

warehouse rooms (this is increased to 35 kN/m² if the height is 6 m or more). In these warehouses, the

height of the pallet shelves as well as the stacking vehicles used are the determining factors for the floor

load.

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2.5 Warehouse lighting

We recommend a light intensity of 300 lux within the entire warehouse area. Often, this can only be

achieved with the use of artificial light.

Above all in a two-level rack system, attention must be paid to achieving adequate light intensity in the

lower area by means of artificial light sources.

2.6 Access ways/doors/gates

The door width must be min. 1.5 m (approx. 4.92 ft). It is recommended that a sectional door should be

used for the goods acceptance area.

A transitional area is required in multi-level rack systems.

2.7 Storage temperature

The warehouse is a continuous workplace as defined by the specifications of the employers'

professional liability insurers, therefore it is necessary to comply with legal specifications relating to

temperatures. It is essential for the temperature specifications to be complied with, also in order to

avoid damaging the spare parts in the warehouse by exposing them to excessively high or low

temperatures.

2.7.1 Storage temperature for tyres (unmounted)

In order to avoid damage during mounting of low-profile or Run Flat tyres, they must have a core

temperature of min. +15 degrees Celsius.

We recommend having a room temperature of +19 degrees Celsius in the tyre warehouse, so that tyres

can be removed for mounting at any time. To achieve the core temperature of 15 degrees Celsius, they

must be stored for up to 8 hours at 19 degrees Celsius, depending on the initial temperature.

Tyres must be stored upright in racks provided for this purpose.

See also the Mounting/Demounting Instructions UHP and Run Flat Tyres (Attachment 1) Warming up

tyres from the wdk dated 22 October 2007.

The fire load in tyre storage rooms is greater due to the increased surface of the tyres without rims, and

often requires sprinkler systems.

2.7.2 Temperature for fluids, etc.

Fluids containing water (e.g. paints) must be stored at a temperature not less than +5 degrees Celsius in

order to avoid front damage.

If the warehouse is to be used for storing special fluids such as paints or the like then the individual

compositions of the fluids must be taken into account, and the temperature adjusted accordingly. In all

cases, we recommend a minimum temperature of +5 °C for the fluids area.

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2.7.3 Storage of complete wheels

Storage temperature:

The storage temperature should not be less than 5 °C and not more than +35 °C. Storage temperatures

higher than +35 °C are only permitted for a few days, and also only if the outside temperature is also

correspondingly high. In any event, a storage temperature below 0 °C must be avoided.

Air humidity:

Adequate ventilation must be provided in order to avoid sustained high levels of air humidity. Basic

requirement: The larger the warehouse space, the better

Inflation pressure:

Where mounted tyres of concerned, the recommended inflation pressure is min. 1 bar.

Arrangement of stored tyres:

Vertical storage, the stacking height of unmounted tyres is not allowed to exceed eight. Wood pallets

are not allowed to be used.

Selection of rooms for storage:

The warehouse room must be dry, without direct sunlight shining onto the stored tyres. The tyres are

not allowed to be stored in the immediate vicinity of equipment which gives off ozone (electric motors,

neon tubes, etc.).

A distance of at least two metres must be maintained from generators, heating systems and stored

solvents.

In addition, the warehouse room should not have any rodent infestation.

Average storage area, depending on warehouse facility, for one wheel set is about 0.5 - 1.0 m².

2.8 Sprinkler system

A sprinkler system is required for certain fire category classifications, or if the room height is 7.50 m

(approx. 24.6 ft), or more. This may be different depending local guidelines.

With sprinkler systems, it is necessary to comply with the minimum spacings between the individual

sprinkler heads.

Alternatively, it is possible to separate off the area by structural means (F180) in order to reduce the fire

loads.

2.8.1 Sprinkler system for spare parts

Specified under fire regulations by local authorities depending on the fire load. We recommend

involving these public authorities in the planning process at an early stage.

2.8.2 Tyre storage

The absence of the rim means that the fire load is significantly increased when tyres are admitted into

the warehouse, as a result of which a sprinkler system is generally required.

The decisive factor is the opinion of the public authority responsible for fire prevention.

2.8.3 Complete wheel storage

Normally, admitting complete wheels into the warehouse does not require any special consideration

with regard to sprinkler systems, because the installed rim reduces the fire load.

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2.9 Other equipment in the spare parts warehouse

The following equipment may also be considered for the warehouse, although it is not dealt with

further in these planning principles:

Washbasin with tap

Waste bins

Transport devices

Containers for holding spare parts

Desk with office chair

PC

Printer/telephone/fax machine

Barrel pallet

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3 Working procedure of warehouse planning

BV-74 exclusively plans locator storage systems in order to utilise the available warehouse area

optimally.

There is no allocation of the storage position to the individual spare parts.

Warehouse management is an iterative process that should regularly be checked for its practicality and

whether it is up to date, and adapted if necessary. Spare parts that do not have a pick count of at least

one are not taken into account in warehouse planning, because this specific spare part should not be

stocked. Depending on the specific lead time, the required spare part is generally available in stock

within 24 hours.

In order to achieve a forward-looking warehouse, it is necessary to take account of flexibility, future

expansions due to growth in parts or restructuring right from the start.

Thus, a self-supporting platform should always be used in multi-level rack systems in order to allow the

BMW rack types to be positioned or moved on the various levels completely independently of one

another. Although the self-supporting platform is more cost-intensive than a platform fixed according

to the BMW rack types, nevertheless this forward-looking investment should be made.

Racks should be designed so that a subsequent conversion can be carried out easily (quickly, without

tools). This is required for adaptations due to changing parts or spare part quantities. Also, rear and

side panels should be able to be inserted or removed subsequently.

Sharp-edged components on racks can lead to injuries to the operating personnel, and are thus not

acceptable.

Furthermore, it is recommended that two 400 mm (approx. 1.31 ft) deep BMW rack types of the same

variant should always be used instead of one 800 mm (approx. 2.62 ft) deep BMW rack type, in order to

retain sufficient flexibility. In this way, for example, subsequently fitting the rear panels would allow

these BMW rack types to be used completely independently from one another.

3.1 Basics

BV-74 assists you with planning (layout diagram, cost estimate).

We define one storage bin for each item, taking account of the stock, pick frequency, lead time, range,

outstanding amount and size of the individual spare parts. The total amounts of these storage bins are

subsequently distributed between the individual BMW rack types. The resulting number of individual

BMW rack types is integrated into the existing building and evaluated.

The ideal rack bay allocations are calculated with regard to the individual part packaging. No deviations

in packaging (such as due to delivery of container packaging) can be taken into account.

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3.2 Received documents

We require the following documents for warehouse planning.

1. DWG file of the building or the warehouse room

2. XLS file of the warehouse stock

3. Filled in "Warehouse planning" questionnaire

We only know the dimensions and weights of BMW spare parts. Therefore, only BMW spare parts can

be taken into account in the warehouse planning as a matter of principle No guarantee is offered for the

accuracy of fit if external brands are integrated into the warehouse, however a specified percentage of

storage area or parts items can be taken into account and provided for.

The parts warehouse should only ever be used for storing spare parts, and not office materials,

decoration materials, brochures, removed parts, special tools, workshop equipment or accessories.

3.3 Documents returned from BV-74

2D layout diagram (dgn or dwg format) with the various rack types and identification of rack rows, as

well as the individual racks.

Parts list (multilingual) with a detailed list of all sensible rack types based on SSI-Schaefer products.

Statement of the max. existing storage bins, sorted by type.

Cost estimate of the rack system with SSI-Schaefer catalogue net prices, not including transport or

installation costs.

Detailed drawings with a list of the individual parts of the rack types used.

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3.4 Warehouse arrangement

The position of the spare parts warehouse in the overall project is of decisive importance for the overall

function of a dealership. In this case, the BMW building standard recommends incorporating the "three

point" into the planning (see building standard). Accordingly, the parts issue for customers and the

parts issue for the service personnel can be carried out from a central location in the spare parts

warehouse.

It is essential for the warehouse to be arranged on the same level as the workshop.

The warehouse is divided into various areas, all of which contribute to an optimum workflow in the

warehouse. The following chapters deal with these areas specifically.

Diagram 6: Arrangement of the warehouse in the building

Key:

1 Showroom, customer area

2 Workshop

3 Spare parts warehouse

3.1 Goods issue

3.2 Goods incoming, handover area, floor storage

3.2.1 Night time delivery

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3.4.1 Possibilities for warehouse arrangement

- Warehouse 100 m²

- Warehouse 200 m²

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3.4.2 Goods incoming, handover area, night-time delivery

The goods incoming area is usually also designed for night-time deliveries.

The handover area is used for transporting goods into the higher storage level using a stacker.

It must be possible to block off the area for night-time delivery from the remainder of the warehouse.

It is recommended for sufficient containers, skips, etc. to be provided in this area in order to allow the

packaging material to be disposed of immediately when unpacking.

3.4.3 Floor storage

Very large, heavy parts may be impossible to store in any BMW rack.

These parts should be used as quickly as possible after being ordered.

In order to allow storage at short notice for campaigns with a limited period (e.g. winter wheels), a

certain area of the warehouse should always be planned for floor storage.

3.4.4 Goods issue

Positioning the goods issue correctly in the warehouse is decisive for the number of warehouse

employees needed. In this case, the BMW building standard recommends incorporating the "three

point" into the planning (see building standard).

Good issue also functions as the rapid pick zone, where parts with high pick rates (generally and

predominantly small parts) are stocked.

We recommend using parts cabinets with drawers for small parts in this area of the warehouse.

© 7/2012 BMW AG, V1.1 25 of 73

3.4.5 Corridors/passageways

Each warehouse has at least one main corridor with aisles running off it.

Aisles are the pathways between the individual rack rows.

Dimensions:

General specifications BMW recommendations

Main corridor 125 cm 150 cm (4.92 ft)

Aisle 75 cm 85 cm (2.79 ft)

(for 40 and 60cm deep racks)

Aisle 75 cm 105 cm (3.44 ft)

(for 80 cm deep racks)

Aisle 75 cm 125 cm (4.10 ft)

(for 80cm deep special racks) windows, sheet metal

parts, etc.

Aisles are generally configured without an exit, and should not be longer than 8 m. If this length is

exceeded, we recommend incorporating additional main corridors parallel to one another.

3.4.6 Stairs

The stairs in the warehouse should have a minimum clear width of 1.00 m (approx. 3.28 ft). The rack

height of 2.3m (approx. 7.55 ft) requires a step length of 3m (approx. 9.84 ft).

3.4.7 Wall distance

We plan the rack systems with a small wall distance of 5 - 10 cm (approx.0.16 – 0.32 ft) . This wall

distance allows angled, crooked walls or items installed in front of the wall (plumbing or electrical

installations) to be compensated for when erecting the rack system. In particular in multi-level systems,

this distance is very important because subsequently moving the rack positions requires reworking and

follow-on costs if the intermediate level is supported by the racks.

26 of 73 © 7/2012 BMW AG, v1.1

3.4.8 Storage location

The signage for the aisles, racks and storage bins can be made according to a standardised scheme with

a seven-digit number.

Example:

Storage location = A 03 02 11

A = Level (level A = ground level, level B = first floor, etc.)

03 = Aisle name starting from the point of sale and in ascending order

the left aisles are odd numbers 01, 03, 05, …

the right aisles are even numbers 02, 04, 06, …

02 = Within the previously stated aisle, the racks are designated in ascending order on the left (odd)

or right (even)

11 = Precise position in the BMW rack

the first number is the vertical position in ascending order from top to bottom

the second number is the horizontal position in ascending order from left to right

The position of the part in the depth of the rack cannot be defined in this 7-digit storage location

designation.

Accordingly, this example storage location is on the level of the goods issue (ground floor), in the first

aisle on the left side, in the first rack on the right and in the bin at the top left of the BMW rack (see

point).

Diagram 7: Warehouse layout

© 7/2012 BMW AG, V1.1 27 of 73

3.4.9 Delivery and installation preconditions

Delivery and installation preconditions

Installation location

- Hall enclosed on all sides

- Ground level

- Normal temperature, constant min. +5 degrees Celsius

- No asphalt

- Magnesite screed only with insulating plates under the rack uprights.

- Thickness of the floor slab min. 200 mm C20 DIN1045

- Levelness of the floor DIN 18202 line 3

- Installation area swept clean and cleared out

- Adequate lighting, electricity, electrical cables available

- Lockable room available for tools

- Toilet available

Delivery and unloading

- Access for 36 tonne truck with a length of 18 m (approx. 59 ft), possible

- Unloading possible in the installation hall Recommended roof height (building) 4.50m (approx.

14.76 ft),

- Unloading from the lengthways side of the truck possible

- Unloading by the client

Bringing in material

- Ground level with stacker

- Bringing in by the client

Material storage

- In hall enclosed at all sides

- In the immediate vicinity of the installation location

- Free access between the storage and installation locations

- Adequate storage area for the entire duration of installation

- In one place throughout the entire installation period

Installation tools

- Forklift truck with 1.5 tonne capacity available

- Lifting platforms, ladders available

Working time, packaging material

- Monday to Saturday from 9:00 to 18:00 hours

- Disposal of the packaging material by the client

Offers are made on the basis of these specifications, and will result in subsequent requirements and

time delays during installation if they are not complied with.

3.5 Site measurements

- Tolerances acc. to FEM 10.3.01

- Metre level available

- Measurements of projecting points such as radiators, ducting, etc.

28 of 73 © 7/2012 BMW AG, v1.1

3.6 Platforms for multi-level systems

Intermediate shelf supported by the racks

(Inexpensive and space-saving)

The uprights (frames) of the rack system have a minimum load capacity of 50 kN.

Structural height of this construction 5cm (approx. 0.16 ft). Given a rack height of 227 cm (approx.

7.45 ft), the overall height of a double rack system is 227 cm + 227 cm + 5 cm = 459 cm (7.45 ft +7.45 ft +

0.16 ft = approx. 15.06 ft)

The room must be min. 5cm (approx. 0.16 ft) higher for installation.

Design:

1. Crossbeams running at right angles to the corridor direction are positioned between the racks,

suspended from all rack uprights. These crossbeams are used for holding lighting on the

underside. All corridors and aisles are covered over by panels or mesh gratings placed on these

crossbeams.

2. Racks of the same dimension can be positioned above the racks.

This results in a second rack level. If the racks are not set up overlapping then the max.

permitted load capacity is reduced.

3. Panels or mesh gratings can also be placed on the shelves in the uppermost position.

This results in a second, level warehouse surface throughout.

Vacant areas (without racks for putting on the crossbeams) require an additional support structure.

The useful space in the racks is not reduced by this construction. The arrangement of lamps at the

height of the rack uprights running at right angles to the aisle direction does not impair removal of

parts from the uppermost rack bin.

Part of the room should not be built over. In this vacant area, parts are raised directly to the second

level by a stacker (transfer location). Such transfer locations must have possibilities for the railings on

the second level to be opened temporarily, whilst simultaneously affording protection against falling.

There must be railings as protection against falling at points where the second storage level is not

bounded by the building. Gaps between this second level and the building structure must be secured to

prevent anyone falling through.

The step dimensions should have a width of 100 cm, length of 300 cm and a landing surface at top and

bottom of 100 cm (approx. 3.28 ft), each.

BMW corridors 850, 1050, 1250 and 1500 mm (approx. 2.78, 3.44, 4.10 and 4.92 ft),

Lighting 300 lux measured 1 m above the floor when using lights in the crossbeams of the suspended

ceiling. Lighting with neon lamps running at right angles to the corridor direction. The arrangement of

lamps prevents casting shadows to the greatest possible extent when the operating personnel is

standing in front of the racks.

It is recommended for cables and lines to be installed in the support profiles.

When installing the lamps in the crossbeams, take measures to ensure a low level of vibration.

Floor coverings must be configured in accordance with the requirements.

Suitable materials are metal gratings, multiplex panels or coated particleboards.

© 7/2012 BMW AG, V1.1 29 of 73

4 BMW rack types for dealerships

Uniform BMW rack types have been defined with warehouse equipment manufacturers, and should be

used in the dealership organisation.

These BMW rack types are designed for BMW Group spare parts, and meet the requirements of a

forward-looking warehouse.

We differentiate between BMW shelf rack types and BMW special rack types.

The definition of BMW rack types was conducted chiefly with attention paid to the variety of variants in

order to give service companies the opportunity of storing the widest possible range of spare parts in

one BMW rack type. Also, consideration was given to the most favourable picking area for ergonomic

operation in order to reduce the strain on parts service employees, to reduce the load carried by

individual shelves and to increase the quality of rack types. As a rule, the load capacity of the two lower

shelves of the rack types is 2000N, with 1000N in the area above (10N is approximately the same as a

weight of one kg).

In all cases, we use a rack height of 2.3 m in our planning. It does not make sense to exceed this height,

because the upper bins are then difficult to access.

Racks with a smaller depth (400 mm / approx. 1.3 ft) give rise to higher warehouse costs than racks

with a large depth (800 mm / approx. 2.62 ft) in relation to the useful area. Also, the utilisation of space

with a larger rack depth is more favourable, because the ratio between rack surface and transport

surface is improved. Nevertheless, it makes sense to have a mix of racks with different depths. Racks

with a depth of 600 mm (approx. 1.96 ft), are highly suited to very many BMW parts, and also have a

good price/performance ratio.

An important feature with racks is the opportunity of simple subsequent conversion (rapidly, without

tools or disassembly of the rack) in order to adapt when parts are changed or if the quantities differ.

For example, it must be possible to convert a 4F rack into a 4O rack without taking a significant amount

of time. Also, organisational material should be interchangeable to the greatest possible extent.

This is only possible by using a plug-in system in which all the shelves of an installed rack system can

be exchanged without making changes to adjacent racks.

Plug-in racks require shorter set-up times than bolted racks, as a result of which installation costs are

reduced.

30 of 73 © 7/2012 BMW AG, v1.1

4.1 Rack designation

Shelf racks

Shelf racks are used for storing approx. 80 percent of all spare parts.

The designation of BMW shelf rack types is based on the following scheme:

1. The leading number indicates the depth of the rack in dm

2. The following letter designates the rack type (layout)

Example:

BMW rack type 6X1

6 Rack depth = 60 cm = 6 dm (approx. 1,97 ft)

X Type

1 Variant

BMW rack types 4F, 6F and 8F have the same bin division, but different rack depths namely 40 cm, 60

cm and 80 cm.

Special racks

Special racks are required for particular products (e.g. windscreens, wheels, metal panels, exhaust,

etc.).

The designation of BMW special rack types is based on the following scheme:

1. The leading letter designates the function of the rack

2. The following number designates the rack types (layout)

3. The two numbers at the end define the width of the rack in dm.

Examples:

BMW rack type R2_13

R Tyre / wheel rack

2 Two useable levels

13 Rack width = 130 cm = 13 dm (approx. 4.27 ft)

BMW rack type W2_10

W Windscreens

2 Two useable levels

10 Rack width = 100 cm = 10dm (approx. 3.28 ft)

© 7/2012 BMW AG, V1.1 31 of 73

4.2 BMW shelf rack types

4.2.1 BMW rack type 4F

(Small parts)

Diagram 8: BMW rack type 4F

Detail: Master Slave Article

Upright frame RR 34322V 2 1 144760

Shelves 100kp ZB 4413V 7 7 27012

Shelves 200kp ZB 4423V 2 2 27022

F/Std Divider TRF-K 4417 40 40 27351

Solid Side Panel SWI 3422 2 1 146660

Cross Bracing KV 31013 1 1 146000

Solid Back Panel RWI 31022 1 1 146720

32 of 73 © 7/2012 BMW AG, v1.1

4.2.2 BMW shelf rack type 4H

(Medium parts size)

Diagram 9: BMW rack type 4H



Shelves 100kp ZB 4413V 7 7 27012

Shelves 200kp ZB 4423V 2 2 27022





© 7/2012 BMW AG, V1.1 33 of 73

4.2.3 BMW shelf rack type 4J

(Medium parts size)

Diagram 10: BMW rack type 4J



Shelves 100kp ZB 4413V 7 7 27012

Shelves 200kp ZB 4423V 2 2 27022





34 of 73 © 7/2012 BMW AG, v1.1

4.2.4 BMW shelf rack type 4M

(Medium parts size)

Diagram 11: BMW rack type 4M



Shelves 100kp ZB 4413V 4 4 27012

Shelves 200kp ZB 4423V 2 2 27022




© 7/2012 BMW AG, V1.1 35 of 73

4.2.5 BMW shelf rack type 4O

(Medium parts size)

Diagram 12: BMW rack type 4O



Shelves 100kp ZB 4413V 4 4 27012

Shelves 200kp ZB 4423V 2 2 27022





36 of 73 © 7/2012 BMW AG, v1.1

4.2.6 BMW shelf rack type 4V

(Small parts + medium parts size)

Diagram 13: BMW rack type 4V



Shelves 100kp ZB 4413V 9 9 27012

Shelves 200kp ZB 4423V 2 2 27022

Container RK 421 30 30 16904

- Label for container RKE 321 1 = 100 pc. 1 = 100 pc. 1720

- Protection film RKF 321 1 = 100 pc. 1 = 100 pc. 1790

Container Divider RKT5/421 54 54 16924

- Label for divider RKE400 1 = 100 pc. 1 = 100 pc. 17920

- Protection film RKF400 1 = 100 pc. 1 = 100 pc. 17930





© 7/2012 BMW AG, V1.1 37 of 73

4.2.7 BMW rack / rack 4V1

(Shelf rack with plastic containers for small and medium parts)



Shelves 100kp ZB 4413V 11 11 27012

Shelves 200kp ZB 4423V 2 2 27022

Container RK 421 60 60 16904

- Label for container RKE 321 1 = 100 pc. 1 = 100 pc. 1720

- Protection film RKF 321 1 = 100 pc. 1 = 100 pc. 1790

Container Divider RKT5/421 72 72 16924

- Label for divider RKE400 1 = 100 pc. 1 = 100 pc. 17920

- Protection film RKF400 1 = 100 pc. 1 = 100 pc. 17930





38 of 73 © 7/2012 BMW AG, v1.1

4.2.8 BMW shelf rack type 4Y

(Parts provision)

Diagram 14: BMW rack type 4Y


Upright frame RR36322V 2 1 144780

Shelves 150kp ZB 9415 V 6 6 38102




© 7/2012 BMW AG, V1.1 39 of 73

4.2.9 BMW shelf rack type 6F

(Small parts)




Shelves 100kp ZB 4613V 7 7 27072

Shelves 200kp ZB 4623V 2 2 27082





40 of 73 © 7/2012 BMW AG, v1.1


(Medium parts size)




Shelves 100kp ZB 4613V 7 7 27072

Shelves 200kp ZB 4623V 2 2 27082





© 7/2012 BMW AG, V1.1 41 of 73


(Medium parts size)




Shelves 100kp ZB 4613V 7 7 27072

Shelves 200kp ZB 4623V 2 2 27082





42 of 73 © 7/2012 BMW AG, v1.1


(Medium parts size)




Shelves 100kp ZB 4613V 4 4 27072

Shelves 200kp ZB 4623V 2 2 27082




© 7/2012 BMW AG, V1.1 43 of 73

4.2.13 BMW shelf rack type 6T

(Small parts)

Diagram 19: BMW rack type 6T

Detail: Master Order

no.

Ground Shelf GR 4602 GE Special height 1 26882

Theken Cover Plate TA 060 1 13690

Solid Side Panel SW 4610 L Special height 2 26490

Solid Back Panel RW 2000 1 12750

Floor Fixing BBF 2 27892

Drawer ESCH 4610L 9 27971

Side Panel SBL-ESCH 4100 9 28260

Insert Boxes EK6161 160 4764



44 of 73 © 7/2012 BMW AG, v1.1

4.2.14 BMW shelf rack type 6T1

(Small parts)

Diagram 20: BMW rack type 6T1


no.

Ground Shelf GR 4602 GE Special height 1 26882


Solid Side Panel SW 4610 L Special height 2 26490




Side Panel SBL-ESCH 4100 9 28260


© 7/2012 BMW AG, V1.1 45 of 73


(Small parts)



no.

Master Shelf GR 4602 GE Special Height 1 26882


Solid Side Panel SW 4610 L Special Height 2 26490




Side panel SBL-ESCH 4100 9 28260

Insert boxes EK 6181 180 4754

46 of 73 © 7/2012 BMW AG, v1.1


(Small parts)


Detail: Master Article

Master Shelf GR 4602 GE Special Height 1 26882


Solid Side Panel SW 4610 L Special Height 2 26490




Side panel SBL-ESCH 4100 9 28260

Insert boxes EK 6141 90 4734

© 7/2012 BMW AG, V1.1 47 of 73

4.2.17 BMW shelf rack type 6W

(Medium parts size)

Diagram 23: BMW rack type 6W



Shelves 100kp ZB 4613V 4 3 27072

Shelves 400kp ZB 4643V 2 3 27082

F/Std Divider TRK-K 4617 10 10 27370




48 of 73 © 7/2012 BMW AG, v1.1

4.2.18 BMW shelf rack type 6X


Diagram 24: BMW rack type 6X

Detail: Mast

er

Sla

ve

Article


Shelves 100kp ZB 4613V 3 3 27072

Shelves 200kp ZB 4623V 2 2 27082

Drawer ESCH 4610L 6 6 27971

Insert boxes EK 6161 240 240 4764





Figure 1: BMW rack type 6X1

© 7/2012 BMW AG, V1.1 49 of 73

4.2.19 BMW shelf rack type 6X1


Diagram 23: BMW rack type 6X1



Shelves 100kp ZB 4613V 3 3 27072

Shelves 200kp ZB 4623V 2 2 27082


Insert boxes EK 6161 240 240 4764





50 of 73 © 7/2012 BMW AG, v1.1






Shelves 100kp ZB 4613V 3 3 27072

Shelves 200kp ZB 4623V 2 2 27082


Insert boxes EK 6181 120 120 4754




Solid Back Panel RWI

31022

1 1 146720

© 7/2012 BMW AG, V1.1 51 of 73






Shelves 100kp ZB 4613V 3 3 27072

Shelves 200kp ZB 4623V 2 2 27082


Insert boxes EK 6041 60 60 4734





52 of 73 © 7/2012 BMW AG, v1.1

4.2.22 BMW shelf rack type 6Y

(Parts provision)

Diagram 27: BMW rack type 6Y


Upright frame RR 36322 V 2 1 144780

Shelves 150kp ZB 49615 V 6 6 28132




130 130

© 7/2012 BMW AG, V1.1 53 of 73

4.2.23 BMW shelf rack type 8F

(Small parts)




Shelves 200kp ZB 4823 V 9 9 27172

F/Std Divider Panel TRF-D 4817 40 40 39660




© 7/2012 BMW AG, V1.1 57 of 73

4.2.27 BMW shelf rack type 8N

(Large parts)

Diagram 32: BMW rack type 8N



Shelves 200kp ZB 4823 V 5 5 27172




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4.3 BMW special rack types

4.3.1 BMW special rack type MP

(Strips, drive belts, cables)

Diagram 33: BMW rack type MP


Mesh panel ZW 210/W 1 1 11380

Double hook 160 / 75 – ZH 2 20 20 11390

Hook label holder ZE 82 20 20 11420

Label ZEE 100 100 11930

Label cover ZEF 100 100 11940

When mesh walls are used, we recommend the use of guide strips with a safety distance on the floor,

and a gap of 25 cm (approx. 0.82 ft) between two mesh walls.

Figure 2: BMW rack type MP

© 7/2012 BMW AG, V1.1 59 of 73

4.3.2 BMW special rack type R2_10

(Tyres, rims, wheels, exhaust)

Diagram 34: BMW rack type R2_10



Crossmember RTR 31015 2 2 147220

Crossmember KTRZ 31036 3 3 147140

Silencer Holder APH 340 5 5 18120

Plywood Panel KRAB 381020 1 1 94830

Frame Connector RV 3300 4 2 147120

62 of 73 © 7/2012 BMW AG, v1.1

4.3.5 BMW special rack type S2_10

(Large parts)

Diagram 37: BMW rack type S2_10



Beam KTRZ 31036 4 4 147140

Plywood Panel KRHH 381020 2 2 94760

© 7/2012 BMW AG, V1.1 63 of 73

4.3.6 BMW special rack type W2_10

(Windows)

Diagram 38: BMW rack type W2_10



Beam KTRZ 31036 6 6 147140

Beam cover strip KRT 3102 4 4 147340

Windshield holder KRA 4950 12 12 159460


64 of 73 © 7/2012 BMW AG, v1.1

4.3.7 BMW special rack type W3_10

(Windows)

Diagram 39: BMW rack type W3_10



Beam KTRZ 31036 8 8 147140

Beam cover strip KRT 3102 6 6 147340

Windshield holder KRA 4950 12 12 159460


© 7/2012 BMW AG, V1.1 65 of 73

4.3.8 BMW special rack type Z1_03

(Hazardous materials)

Diagram 40: BMW rack type Z1_03

Detail: Master Article

Hazardous materials cupboard FK12-3 1 198140

Collection tray BAW 125 1 198110

Shelves FGSWBS12 3 199030

Circulating-air filter unit UFA 1 193860

66 of 73 © 7/2012 BMW AG, v1.1

5 Sliding carriages

In order to reduce the warehouse area, racks can be placed on carriages, and moved from side to side.

These carriages enable several adjacent aisles to be replaced by one. In each case, only the aisle that is

required for removing parts is opened up.

Carriages allow the warehouse area to be reduced by up to 40%, with the same storage quantity.

Figure 1: Racks on sliding carriage

When these sliding carriages are used, it is necessary to have 15 cm more room height (assuming the

rack uprights are not shortened) above the entire sliding area. Also, it is not possible to withdraw parts

simultaneously from all racks.

As a rule, the carriages cost only a portion of the amount saved by reducing the room space.

The sliding carriages do not impose greater requirements on the floors.

To enable racks to be positioned on sliding carriages, it is necessary for the depth to height ratio not to

exceed 1:5.

A maximum of 5 racks can be positioned in a row on one carriage. 3 rack rows are mounted on each

carriage. The individual carriages require a minimum distance of 180 mm (approx. 0.59 ft), from the

wall. The carriages only require a guide rail in the wall area, but do not need travelling rails. It is

essential to have a fixed connection between all of the racks and between the racks and the carriage.

© 7/2012 BMW AG, V1.1 67 of 73

6 Wheel storage

6.1 Possibilities for wheel storage

Wheels and tyres must be stored vertically, and not on square-edged support sections.

There are basically 4 possible ways of storing wheel sets. The possibility that is selected depends on the

spatial conditions. Double-depth storage is recommended from a cost/benefit perspective.

The possibilities referred to are assessed below, assuming a specified internal room dimension of 10 x

15 m (approx. 32.8 x 49.2 ft). The room height has been assumed to be variable.

The wheel dimensions are assumed to be as follows: for diameters up to 75 cm (approx. 2.46 ft), widths

up to 32 cm (approx. 1.04 ft); for diameters up to 65 cm (approx. 2.13 ft), widths up to 23 cm (approx.

0.75 ft). This covers 80 percent of the wheel dimensions on BMW vehicles. The prices are in line with

German market prices.

6.1.1 Single-depth storage

In single-depth storage, one wheel takes up the depth of the rack, and can be accessed from each side

of the rack. This means that additional aisle space is required. Given the height of 2.45 m, it is possible

to store 3 wheels in any event, irrespective of the wheel dimension.

Minimum room height Costs per wheel set Number of wheel sets Area / wheel set

2.45m (approx. 8.03 ft) € 33 290 0.52 m²

2.97m (approx. 9.74 ft) € 30 358 0.42 m²

3.75 m (approx. 12.3 ft) € 28 458 0.33 m²

Diagram 41: Wheel store with single depth

68 of 73 © 7/2012 BMW AG, v1.1

6.1.2 Double-depth storage

In double-depth storage, two wheels are stored across the depth of a rack, and can be accessed from

each side of the rack. This reduces aisle areas. Given the height of 2.45 m, it is possible to store 3 wheels

in any event, irrespective of the wheel dimension. Given the same room division, it is possible to store

at least 82 wheel sets more with this storage possibility than in single-depth storage.


2.45m (approx. 8.03 ft) € 33 372 (+ 82) 0.40 m²

2.97m (approx. 9.74 ft) € 30 444 (+ 86) 0.34 m²

3.75 m (approx. 12.3 ft) € 28 652 (+ 194) 0.23 m²

Diagram 42: Wheel store with double depth

© 7/2012 BMW AG, V1.1 69 of 73

6.1.3 Four-deep storage

In four-depth storage, four wheels are stored across the depth of a rack, and can be accessed from each

side of the rack. This reduces the aisle areas even more. However, given a height of 2.45 m, it is only

possible to store the following wheel combinations, assuming 3 wheels are located one above the other:

- 2 wheels one above the other with up to 65 cm wheel diameter

- 1 wheel below with up to 75 cm wheel diameter.

Given the same room division, it is possible to store approx. 44 wheel sets more with this storage

possibility than in double-depth storage.


2.45m (approx. 8.03 ft) € 70 to 80 416 0.36 m²

3.25 m (approx. 10.66 ft) € 70 to 80 564 0.27 m²

If only wheels with a size of 75 cm wheel diameter are stored, either the 2.45 m would not be sufficient,

or it would be possible to store 2 wheels one above the other. Given the same room division, this

storage possibility would result in accommodating approx. 30 wheel sets fewer than in double-depth

storage, although the costs would be almost 3 times as much.

Diagram 43: Four-deep wheel store

70 of 73 © 7/2012 BMW AG, v1.1

6.1.4 Mobile storage using sliding rack

With mobile storage, the accessibility is the same as with single-depth storage. This reduces the aisle

surfaces, because the racks can be moved.

This possibility is an interesting option if there is greater height available. However, the racks are not

suitable for wheels with a size >65 cm wheel diameter, because the wheels then exceed the rack width.

Diagram 44: Mobile wheel store

© 7/2012 BMW AG, V1.1 71 of 73

7 Storage of parts in general

Shock absorbers and suspension struts are allowed to be stored both horizontally and vertically.

Batteries are stored on normal shelves which have adequate road capacity.

Hazardous substances are stored in closed, appropriate cabinets.

Flammable liquids are stored in accordance with the technical rules for flammable liquids (e.g. TRbF in

Germany).

72 of 73 © 7/2012 BMW AG, v1.1

8 Annexes

8.1 Attachment 1 Extract from the Mounting/Demounting Instructions by the wdk dated 22

October 2007.

wdk

Mounting/Demounting Instructions

UHP* and Run Flat Tyres** Attachment 1

Warming up tyres

* Aspect ratio ≤ 45 % and speed symbol ≥ V

** Pay attention to manufacturer‘s marks

Wirtschaftsverband der deutschen 22 October 2007

wdk

Kautschukindustrie e. V. Page 1

Recommendation to warm up cold tyres

to a minimum mounting temperature of +15°C

So that tyres can be mounted without any risk for operator and equipment, the upper tyre sidewall and

the upper bead must have an inside temperature of at least +15 °C.

This inside temperature is called core temperature.

Rubber is a poor heat conductor. Consequently a cold tyre must be stored in a well tempered

environment for some time to make sure the inner rubber layers have warmed up to at least +15 °C.

During the warming up phase the surface temperature of the tyre is no indication for its inside

temperature!

Room temperature is usually measured and read at eye level. When temperature is 19 °C at eye level,

temperature at ground is around 16 °C. Consequently cold tyres should not be placed directly on cold

ground for warming up, but at least on an insulating base, a pallet, or even higher.


wdk


© 7/2012 BMW AG, V1.1 73 of 73

Recommendation to warm up cold tyres

to a minimum mounting temperature of +15°C

So that cold tyres warm up rather quickly, they should not be stacked up, but stored separately, so that

warm ambient air is allowed to circulate around them.

Tyres should not be warmed up using a radiant heater, or a warm-air blower, as such devices easily

produce detrimental surface temperatures. There is no procedure except warming up in warm water, or

warm ambient air (50 °C maximum, by no means hotter!) by which a tyre can be warmed up without

any adverse effect!

If cold tyres (less than 0 °C) are taken into a warm environment (more than 0 °C), condensate forms and

freezes at once on the tyre surface. This frozen condensate shows that the tyre intensely absorbs heat

from the environment. When the frozen condensate melts it should be wiped off with a cloth so that

further warming up is not delayed through cooling caused by evaporation.


wdk Kautschukindustrie e. V. Page 3

Summary

Assuming a room temperature of at least 19 °C: • Tyres initially having a temperature of 0 °C and more: store for at least 2 h,

• Tyres initially having a temperature of less than 0 °C: store for at least 2 1/2 h.

Recommendations for warming up: – Store on insulating base, pallet, or the like, as high as possible, the „upper“ bead being on top

– Store tyres separately so that warm air is allowed to circulate well around.

– Wipe off condensate

– Do not expose to heaters!


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