presentation wdf 2017.ppt - enfasis.com · david fredde. think and plan 2 when you are lucky enough...
TRANSCRIPT
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Smarter-Faster-Safer
…Determine and Identify your Intra-Logistics Needs
Presented by:
David Fredde
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Think and Plan
2
�When you are lucky enough to have time to
play a game of pool!
�You want to aim straight!
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Presentation Outline
1. Understanding your Intra-Logistics Challenges� 6 Pack of Challenges
� Cost of an Error
2. Systematic Analysis� The Big 12
� Business Drivers
3. System OverviewsPerson to goods
� paper, � Voice
Smart Conveyor Networks� Zone Route� Induct
Goods to person� Automated Pick Station � Put Wall
Batch pick & sort� Single SKU Batch Pick� Sort to Order
Software
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Understanding your Intra-Logistics Challenges
�6 Pack of Challenges
�Cost of an Error
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Understanding Your Intra-Logistics Issues6-Pack of challenges
Inventory, SKU Growth
Accuracy
Energy, Green,Transportation Costs
Labor, ErgonomicsSpace Utilization
Throughput & Processing time
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Cost of an Error
Actual Costs:
� Administration hours (phone calls, data entry, re-order, etc.)
� Contact & apologize
� Shipping cost to return & re-ship
� Special delivery cost
� Returns handling, processing, restocking
� Labor hours in inventory control
The BIG Cost
�Customer goodwill
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Systematic Analysis
�The Big 12
�Business Drivers
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Activity Profiling “The Big 12”
1. Orders per day
2. Daily unit volume
3. Units per order
4. Lines per order
5. Packing sequence
6. Unit cube & cube movement
7. Unit structure
8. Cartons per order
9. Total SKU’s
10. % daily SKU’s active
11. Order download
12. % volume cross-docked
• Review historical data
• Forecast future activity
The systematic analysis of the items & orders handled in the DC
determines the optimum design & operation
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Business DriversThat affect order fulfillment system design
� Accommodate spikes in throughput (special promotions, seasonal, etc.)
� Accommodate more SKUs than competitors
� Perform order fulfillment on 1 shift of operation
� Expandability for future growth
� Maximize ergonomic design
� Extend order cut off time
� Initial investment cost
� Manageability
� Total labor
� Accuracy
� Security
� Space
� Speed
� Other
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Types of Solutions
�Solution Sets
�What to expect
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The Solution Sets
Person to Goods
Goods to PersonSmart Conveyor Networks
Batch Pick & Sort
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Productivity – What to Expect?uplh: units per labor hour
Person to goods
Smart Conveyor
Batch Pick
& Sort
Goods to Person
500 400-500 uplh
150 100-150 uplh
60-80 uplh
300 100-300 uplh
total units picked
total labor hours(replenishment & pick/pack)=uplh
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System Overview-Person to Goods
�Paper �Voice to Cart
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Example - Discrete Pick to Cart Using Shelving
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Application Profile & Market SectorsBatch Pick Voice Carts
Application Profile:
� Split case, piece pick operations
� Low - mid rate: 500 – 10,000 orders/day
� 1-20 items per order
Market Sectors
� Wholesale & customer Direct
� Motorized vehicle parts
� Commercial eq. supplies
� Computer eq. & software
� Medical supplies
� Electrical eq. supplies
� Electronic parts
� Hardware supplies
� Construction eq. supplies
� Industrial machinery supplies
� Jewelry, watches
� Office & paper supplies
� Drugs
� Retail & whls. apparel
� Publishing
� Sporting goods
� Medical devices
� Personal care
� 3PL
� Customer Direct
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Batch Pick CartsVoice Directed
� Multiple orders per cart
� Optimize picking productivity
� Scan location
� Voice instructions
� Optimized pick paths
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Pick Path
� Wide aisles
� Multiple carts
� Pick path: Z pattern
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Put to PalletVoice Directed
Inbound Product
Voice Directed
Put to Pallet
Receiving
Shipping
� Full pallet in
� Build mixed case pallet
Voice Directed
case put to pallet
� Quick turn inventory/cross dock
� Increase productivity
� Reduce touches
� Reduce order processing time
� Rule enforcement
� Product tracking
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System Overview- Smart Conveyor Networks
�Induct�Zone Route
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Inducting an order
� Multiple induct points
� Scan license plate on tote
� Scan invoice (printed by host)
� Print shipping label
� Place invoice, shipping label in postal bag
� Place bag in tote & then conveyor
Zone route conveyor network
Order induction, print shipping label
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System Overview- Goods to Person
�Automated Pick Station �Put Wall
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Goods to PersonRequires Less Space
storage shuttle buffer conveyor
maintenance mezzanine
elevator
elevator buffer conveyor
product cross conveyor pick station
order routing conveyor
order buffer conveyor
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The Picking Process
Pick from
� Optical Identification
� Complete tote or compartment highlighted with light beam
� Light curtain checks pick from position
Pick to
� Put to light display
� Indicates carton & qty
Weigh scale
� Checks quantity picked
� 5 scales per station
1 2 34
5
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Goods to PersonPut Wall
The Concept:
�Sort to Put Walls (light directed)
� Pack Wall on back side (light directed)
� 1 or 2 persons per station (flex up/down)
The Obtainable Results:
� “Put Wall” stations flex up to peak demand
� Improved order fulfillment accuracy
� Reduced order processing time
� Increased labor productivity
Put Wall
Pack Wall
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Put StationAccommodate Precise Sequencing of Orders Example: 18 put locations, light directed
� Scan SKU tote
� Activates lights
� Put to order carton
� Carton flow rack
� Build pallets at back end
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System Overview- Batch Pick and Sort
�Single SKU Batch Pick�Sort to Order
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Batch Pick & Sort
Parallel batch pick
Item induction
Order Assembly & Pack
Packingchutes
Shipping
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Packing Chute Design
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Batch pick & sort
Potential Issues:
� Out of capacity, inefficient processing
� Need to reduce order processing time
Potential Solution:
� Re-engineer material flow
� Order consolidation sorter, & chutes
� Shipping sorter, software, & controls
Realistic Results:
� From 70,000 to 180,000 items, multi-piece order system capacity
� From 3 shifts/day, to two shifts/day (reduce labor & order processing time)
� From 22 items shipped per labor hr. to 26
� Same day shipments from 25% to 50% (or more)
� Improved Ergonomics
� Accommodate future growth
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Software
�Control and Monitoring�Performance Reports
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ADDITIONAL ADVANTAGESSoftware Dashboard - GUI Real Time Control & Monitoring
� One screen view
� At-a-glance metrics
� Lines complete
This information can
assist with picker
allocation and work
flow
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Think and Plan
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�When you are lucky enough to have time to
play a game of pool, you want to aim straight!
�Yet you should also think about where you
want the white ball to end up after your shot!
�With the correct plan you can achieve more
than one shot if you THINK AND PLAN!
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Dematic and WHY!
Intra-logistics Solutions for Production & Distribution
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Operations approach:
Non biased
Data driven
Process improvements
Business case ROI
Method:
Current state analysis
Operations planning
Process flow engineering
System design & layout
System design evaluation
Strategic/tactical planning
Solution Development EngineeringPractical design & methodology
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�Simulation Modeling
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Return on Investment
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OptimizeOptimize IncreaseIncrease
� Throughput, accuracy
� Efficiencies, performance
� Ergonomics, safety
� Capacity, profits
� Space requirements
� Fulfillment time
� Labor, costs, injuries
� Errors, transactions
� Material & information flow
� Processes
� Activities
� Inventory
ReduceReduce
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Type: non-mechanized, automated, integrated
Capacity: low, mid, high
Size: small, medium, large
System Configurations
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Modular & StandardizedScalable & flexible
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�1. Products – conveyor, shuttle,
sensor, drive�2. Modules – collection of products
assembled to perform a specific function
Defined functionality
Pre-engineered, pre-tested
Consistent performance
Easier to support �System Solution built
on subsystems
�3. Subsystems –
collection of modules &
products to perform a
warehouse function
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For Additional Information:
CONTACT:
David Fredde
Home Page: www.dematic.com/es-mx/