validation using simulation of a new cross docking facility design presenters: josé antonio mesa r....
TRANSCRIPT
Validation Using Simulation of a New Cross Docking Facility Design
Presenters: José Antonio Mesa R.Diego Mesa R.
Javier Orjuela C.
Universidad Distrital “Francisco José de Caldas”Bogotá, Colombia, South America.
Validation Using Simulation of a New Cross Docking Facility Design
Team:Javier Orjuela (Director)
José Antonio Mesa R.(Developer)Diego Mesa R. (Analyst)
Guillermo Urrutia (Designer)Francisco Soler (Designer)
Universidad Distrital “Francisco José de Caldas”GICIC Research Team
Bogotá, Colombia, South America.
Sponsors:
Two Bogotá´s City Hall agencies: Fondo Local de Desarrollo de Ciudad Bolívar.Unidad Ejecutiva de Servicios Públicos. UESP.
Abstract
Simulation with ProModel is being used succesfully in the validation process of a new logistic cross docking facility in Bogotá, Colombia, as part of a Master Plan intended to optimize the logistic process of food suplying and make possible, thanks to cost lowering, an efficient and economic solution for poor communities, and stablishing a proven technology for furthers developments.
Presenters
Javier Orjuela C. MSc Operations Research. Production Engineering Specialist. Industrial Engineer. Former experience in food plants.
José A. Mesa R. Production Engineering Specialist. Computer Science Engineer. Former experience managing production plants and Simulation projects.
Diego B. Mesa. Business Manager. Operation Management Specialist. Logistics Specialist.
Application Summary
The Universidad Distrital was contracted to develop a Market Study in order to build a whole new Food Distribution System intended to reduce the cost of food (It has been estimated that 1´000.000 people in Bogotá have only a food at day)
Important inefficiencies had been found, and they generate a lot of wastes, increasing cost for the final consumer
The second phase of the project lead to design a network of logistics facilities, using the market studies results.
Application Summary
A kind of facility must satisfy the market demand for a specific geographic zone, and its physical design and it procedures must be tested before making any final choice.
The Simulation Model is being developed as part of the works of GICIC research group
Agenda
The problem The City Hall Food Suplying Master Plan The Model
Goals Model Inputs Recomendations
The Problem Validate the Design of a Crossdocking Facility where
goods will be received via heavy trucks, organized temporaly in pallets and then disposed according summarized purchase orders sent to five logistic zones using smaller vehicles
The facility must operate up to 230 tons of food daily, classified in 33 different items, this agregated demand satisfy the requirements of 272.060 habitants and delivered through a network of 807 small stores located on an average distance of 1.6 kms.
The model should allow formulate policies and deploy strategies to balance resources allocation to processes inside the facility
Bogotá, Colombia, South America
Briefing of Bogotá food supplying problem Bogotá is a city of 7´000.000 people. Extremely Poor overpopulated communities,
about 30%, could have only a meal at day They have a dietary deficience: only receive
46% of required calories and 20% of required proteins
With extremely low salaries and laboral inestability, families uses 31% of their incomes in “nutritional” requirements
Between 65 and 70% of the food market is buyed daily at the “corner´s store”
But Bogotá could be “Well Supplied”
Bogota requires about 10.000 tons of food daily
33% comes from the Ring one, Bogotá and 19 other near cities
44% comes from the Ring two, 4 near provinces
23% comes from the country and the world
But Food supplying has been diagnosed “Chaotic and inefficient”
Inadecuate handling can produce at least 17% of wastes
Packaging wastes are 9% of the total mass transported
Big dealers and retailers operations adds 21% to cost
Food marketing infraestructure underutilized
Truck fleet is used only at 48%
Bogotá´s Food Supplying Master Plan
A public policy to ensure that population will have acces to the consumption of meals and nourisments in conditions of: Quantity Variety Quality and Inocuity
Plan Principles
Promote Food Access
Citizens
Enviromental
Sustainability
SAAB (Food Supplying System)
SAAB will allow that producers and small store owners can deal directly makin easier for they his operation in a supply chain knowing offer, demmand and prices.
Improves costs because minimices the quantity of intermediaries and transport
Food are well handled, processed and transported Improves life quality for the whole population
Facilities (Equipments, Infrastructure)
Logistics Management System Quality System (ISO9000, ISO14000, HACCP) Information System
AGRORED NUTRIRED
Op
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SGL
SGC
SGI
infraestructuraLogística
Facility before the project
The Model
Main Goal: Validate one Design of the future Cross Docking Facility
Design: Physical Functional Procedural
Modeling the system’s components and operations the team wished to obtain a simulation model to test, plan and manage the facility, identifying the possible bottlenecks and causes, capacity restrictions, possible response to different load levels, optimal resource quantities, trucks arriving schedule, results of contrasting technologies and required room to fit needs.
Main Features
Complexity Deterministic Reutilizability Visualization Flexibility
Constraints
Platform works from: 04:00 to 08:00 Receiving (loading) 08:00 to 17:00 Delivering (Unloading)
Only One direction at time, it means, You´re loading or you´re Unloading, and you must finish loading to start unloading.
Area: 3000 sq mts (~27000 sq ft)
Complexity
83 locations 35 entities (Trucks, baskets, pallets) 3 lines of items:
From milk to cheese (dairy) and poultry to meat. 6 types of entities.
From tomatoes to Bananas. FRUVER. Fruits and Vegetables. 11 types of entities.
From Sugar to Noodles. Groceries. 13 types of entities.
Two Path Networks, 90 nodes
Complexity
8 resource types (Delivering Trucks, forktrucks, pallet trucks, operators, lifters)
Entity Attributes making easier programming. Entity basket uses an attribute that allows to determine the type of item, making easier the programming process
Processing
// Abarrotes // El peso en toneladas del camion es: At_carga_en_camion *
Array_kilos_canastilla[At_Tipo_producto] // Si viene con mas de 8 toneladas se descarga con 4 operarios
a 4 ton/ min, // sino a N(7.5 , 1) ton por min con dos operarios IF At_carga_en_camion *
Array_kilos_canastilla[At_Tipo_producto] < 8000 THEN USE 2 Op_descarga FOR (At_carga_en_camion *
Array_kilos_canastilla[At_Tipo_producto] * N(7.5 , 1) / 1000) ELSE USE 4 Op_descarga FOR (At_carga_en_camion *
Array_kilos_canastilla[At_Tipo_producto] * 4 / 1000) ORDER At_carga_en_camion ENT(At_prod_en_camion) TO
Cola_ZI1
How the three lines were chosen
Trying to balance the quantity of baskets loaded per line to the facility to ensure a permanent flow
A previous market study was developed by GICIC research team These quantities were used to design the ideal fleet size and
scheduling for loading platform
Leche, 43730Papa, 19290
Citricos, 18010Platano, 16080
Arroz, 13120Carne de res, 7400
Harina de tigo, 6650Zanahoria, 6430Papaya, 6430Banano, 6430
Huevo, 6000Pollo, 5470
Tomate, 5200Menudencias, 5180Aceites, 4500Panela, 4340
Cebolla, 3440Arveja verde, 2890
Leguminosas, 2730Guayaba, 2400
Yuca, 2310Chocolate, 2190
Sal, 1980Queso, 1930Pasta, 1930
Frijol, 1610Azucar, 1190
Visceras, 610Espinaca, 380Acelga, 140
0 5000 10000 15000 20000 25000 30000 35000 40000 45000
Kilogramos
DescripciónProductos
Demanda (en Kg) por tipo de alimento
Milk, potatoes, oranges, plantain and rice are the top five, 55% of consumption!!
Arrays
Five arrays are loaded from an Excel File
Demanded baskets for each product
Kg of each product in a basket Basket per pallet Baskets per truck
Carga de arreglos en PromodelEl arreglo Se carga con ColumnaArray_kilos_canastilla movidaArray_canastillas_estiba canas/estibaArray_demanda Numero de EntidadesArray_canast_camion Canas/camionArray_cargado Canas/camion
Producto Nombre Kilos Kilos/Unidad Numero de Entidades Entidad Camiones Canas/camion Canas/camion canas/estiba
Numero Descripción Demanda movida representa requeridos teóricas Asignadas
1 Leche 43730 24 1822 Canastilla 3.6441667 208 216 242 Queso 1930 25 77 Canastilla 0.386 200 210 353 Carne de res 7400 25 296 Canastilla 1.48 200 210 35
29 Banano 6430 25 257 Canastilla 1.286 200 210 3530 Guayaba 2400 15 160 Canastilla 0.48 333 360 60
Shifts
Facility Load resources and locations (0400 to 0800 hrs)
Facility Unload resources and locations (0800 to 1700 hrs)
Mixed
Load operators, movers,
Unload operators, people preparing orders, deliery trucks
Fork trucks, pallet trucks
Shifts
Loadingfacility
Unloadingfacility
Atributes
Model inputs (arrivals file)
An Excel File containing registers of trucks arriving to the platform, arrival time, type of product and baskets quantity transported in each truck.
This is the base of flexibility
Nombre Location Qty Time Ocurrences Freq. At_Tipo_producto At_linea_camion At_carga_en_camionCamion Oferta_agregada 1 240 4 45 1 3 456Camion Oferta_agregada 1 380 1 45 2 27 77Camion Oferta_agregada 1 240 1 45 3 8 296Camion Oferta_agregada 1 380 1 45 4 31 24Camion Oferta_agregada 1 280 1 45 5 16 207Camion Oferta_agregada 1 280 1 45 6 14 218Camion Oferta_agregada 1 320 1 45 7 17 375Camion Oferta_agregada 1 380 1 45 8 28 321Camion Oferta_agregada 1 380 1 45 9 30 47Camion Oferta_agregada 1 380 1 45 10 25 99Camion Oferta_agregada 1 380 1 45 11 24 87Camion Oferta_agregada 1 240 1 45 12 7 1049Camion Oferta_agregada 1 320 1 45 13 21 218Camion Oferta_agregada 1 380 1 45 14 29 128Camion Oferta_agregada 1 320 1 45 15 18 434Camion Oferta_agregada 1 280 1 45 16 13 4347Camion Oferta_agregada 1 240 1 45 17 9 133Camion Oferta_agregada 1 240 2 45 18 4 482Camion Oferta_agregada 1 240 2 45 19 6 322Camion Oferta_agregada 1 320 1 45 20 23 115Camion Oferta_agregada 1 280 1 45 21 15 260Camion Oferta_agregada 1 320 1 45 22 19 286Camion Oferta_agregada 1 280 1 45 23 10 428Camion Oferta_agregada 1 380 1 45 24 32 76Camion Oferta_agregada 1 380 1 45 25 26 14Camion Oferta_agregada 1 320 1 45 26 20 144Camion Oferta_agregada 1 240 1 45 27 5 720Camion Oferta_agregada 1 280 1 45 28 11 357Camion Oferta_agregada 1 280 1 45 29 12 257Camion Oferta_agregada 1 320 1 45 30 22 160
After loading is complete…
Start preparing purchase orders, send trucks (3 tons) and deliver them to five different logistic zones!!!
Output processing
Groups of orders are prepared inside each delivering truck and sent to each one of five logistics zones
Final orders per store are prepared at the store front
This proces was not detailed deeply, the main scope were operations inside the platform
Final design after adjustments
Final design after adjustments
Final design after adjustments
Dynamic Plots
Benefits
Number of Parking lots for Trucks in system were determined (14)
Trucks permanence in system (average 84.21 minutes) was determined
Future Aplications
Test other 17 platforms (City Logistics) Define costs and Include ABC
methodology Create a Big model Once running, stochasticity will be
measured and implemented to the models
Thanks!!
José Antonio Mesa R. [email protected]
Diego Mesa R. [email protected]
Javier Orjuela [email protected]