OMSAN LOJİSTİK. Session 1 – Morning Defining the Problem Context - Supply Chain, Distribution Network - Single Warehouse Operations Logistics Activity Profiling. Session 3 – Morning Process and Technology Alternatives Small Item Picking - Order Picking Methods
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What should one expect to pay for . . .
A lift truck? How about the battery?
How fast does a fork truck travel? An AGV?
How many cycles per hour can you achieve with . . .
A fork truck into and out of standard rack?
A turret truck into and out of Very Narrow Aisle (VNA) rack?
An Automated Storage and Retrieval System (AS/RS)?
An Automated Guided Vehicle (AGV)?
A double-deep reach truck . . .
To the first position?
To the rear position?
What does pallet storage mean for your operation?
In new or “greenfield” projects, pallet storage requirements often define “how big” you need to make the box
In retrofit/re-engineering projects, pallet storage definition and selection determines “how much can I fit” into the current facility*
In either case, your pallet storage and retrieval decisions are heavily impacted by your business model
*TPG often refers to this as our “9 Pounds In a 5-Pound Bag” program
Retrieval equipment/system modes
Storage/retrieval mode relationships
Storage/retrieval mode functional and cost comparisons
Mode selection and sizing factors
Narrow aisle(8-10’ aisle)
Very narrow aisle(4.5-6’ aisle)
Aisle to aisle
Automated storage/retrieval(4-5’ aisle)
High rise 40-100’
Requirement for FIFO & lot control
Typical receipt size
Handling unit received versus handling unit shipped
Turn rate of storage unit
Overall storage requirement
Pick from storage versus pick from forward area
Random versus storage capability
Computer visibility of locations and inventory
Special needs, e.g. aerosol, chemicals . . .
Utilization study of existing operations - measure current floor space requirements and factor in future business growth
Measure current cube requirements and reapply to new storage equipment
Historical database analysis—by SKU, analyze historical inventories, receipt sizes and sales velocity and factor in business growth
ABC product/SKU analysis—categorize each SKU into classes by sales velocity:
Establish inventory targets by class
Multiply SKU cube x inventory target and sum
Service level expectations - Establish SKU or family target inventories based on economic order quantities, lead time variability, margins
Off-Site Floor Storage
Pallet Flow Lanes
Double Deep Rack
Small Parts Storage
20,000 sq. ft. available for unit load storage . . .
100’ wide x 200’ long
40’ clear height
Just to be nice, there are no columns
The 100’ wide ends are both open, the 200’ sides have walls; material flows in one end and out the other
Loads are . . .
Palletized, stretch wrapped, and highly stable
Uniformly 40” wide x 48” deep x 60” high, each holds 100 cases
Floor stack height is 3 loads
Compare pallet capacity for two scenarios:
Per our spec, we need 2 12’ aisles, leaving 76’ of width, therefore . . .
200’/4’ = 50 pos
76’/4’ = 19 pos
19 x 50 = 950 pos
x 3 high = 2,850 pall
X 100 cs/pall = 285K cs
This one gets a little trickier, because you need to figure out how many aisles and racks you can fit in the space. In this example, one complete aisle and rack is 14’ (5.5’ aisle plus 2 x 4’ racks plus 6” flue between racks).
Which scenario was better? Why?
Why did the VNA solution yield so much more capacity?
Which is more flexible?
Which is more costly to implement?
Why would you choose one over the other?
Could you imagine a hybrid situation in which both modes may be indicated?
In this example, the facility had a high proportion of 10-deep bulk storage lanes. As the data shows, very few SKUs are right for 10-deep storage. The facility will be more efficient with a blend that includes shallower lanes and more facings.
Use sensitivity analysis to understand and explore risks
Determine if it is better to invest on the high side vs. adding incremental space later.
Have plan established for dealing with too little space
Build on or add to lease
Drop ship to customers
Improve turns on high cube items