chapter 8: storage and handling also chapter 12 pp. 470-475 warehousing purposes warehouse...
TRANSCRIPT
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Chapter 8: Storage and Handling
Also Chapter 12 pp. 470-475
• Warehousing Purposes
• Warehouse Alternatives– Public, Private, Direct– Materials Handling– Costs
• Warehouse Layout
• Order Picking
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Inventory
• Inventory (storage) is movement in time.– Transportation is movement in space.
• Inventory cost is 2nd largest component of logistics cost.– Generally 10-40% of total.
– $328 billion in U.S. in 2001
– Large companies have billions of $ in inventories.
• Nearly all logistics cost savings since 1987 have been from reduced inventories!
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Why Store Goods?
• Economies of scale in production & transportation.
• Coordinate supply and demand.– Seasonal products.
• For example: 60% of toys are sold in holiday season.
• Note: <5% of toys are produced in U.S.
– Speculation.• Feb. 2002 - Ford wrote off $1 billion in precious metals.
• Customer service.
• Part of production.
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Warehouse Purposes
• Holding inventory.– Safe storage of goods.
• Transshipment.
1. Consolidation.
2. Breakbulk.
TL
TL
LTL
LTL
LTL
LTL
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Warehouse Purposes - cont.
• Transshipment.
3. Mixing.
LTL
TL
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Velocity
• Cycle time and transit time are decreasing.
Cycle Time Transit Time 1990 83 hrs 54 hrs1995 58 hrs 41 hrs2000 49 hrs 37 hrs
• Turnover ratios are increasing.
Plant Field Warehouse Warehouse1990 8.8 8.91995 10.7 9.42000 11.2 10.2
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Warehouse Alternatives
• Direct shipping (no warehousing).
• Private warehousing.+ Better control, Special needs, Future use of space.—High fixed cost, Constant size and location.
• Public warehousing. + Inexpensive for small amounts, Can vary size and
location, Can provide additional services (customs,etc.). —Less control.
• Combination of public and private.
• Storage in transit.
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Products & Warehouse Alternatives
Private Public Direct
Durable goods 67% 20% 13%
Food products 57% 31% 12%
Paper 65% 10% 25%
Chemical 40% 38% 22%
Automotive 86% <10% <10%
Electronics 84% <10% <10%
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Materials Handling
• Loading and unloading.
• Movement to and from storage.
• Order picking.
• Economies of scale: Larger loads are more efficient.– Pallets: 40” x 48” x 6”
– Slipsheets: 40” x 48”
– Containers: 8’ x 8’ x 20’, 8’ x 8’ x 40’
• Containers also function as warehouses.
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Materials Handling Equipment
• Hand trucks.
• Forklifts.
• Automated systems:– Conveyers, Draglines, Automatic guided vehicles.
– ASR (Automated storage and retrieval systems).
• Container handling.– Expensive special purpose equipment.
• Bulk handling (coal, grain, etc.) requires special equipment.
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Warehouse Costs
Fixed Variable
• Public 1 5
• Leased 2 4
• Private - Manual handling 3 3
• Private - Pallet/Forklift 4 2
• Private - Automated 5 1
• 1 = lowest cost
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Warehouse Costs
cwt Handled
Tota
l Cos
t
Public
Private - AutomatedPrivate - Manual handling
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Warehouse Costs
cwt Handled
Tota
l Cos
t
Public
Private - AutomatedPrivate - Manual handling
Use Private - AutomatedUse Private -
Manual handlingUse
Public
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Warehouse Layout
• Divide floor space into areas for storage, aisles, packing, offices, etc.
• Tradeoff:– Ease of handling vs. Utilization of space.
– Minimize handling and maximize space utilization.
• Storage Layout for low turnover items.– Narrow aisles, wide and deep storage, high shelves.
• Layout for order picking.– Wide aisles, easy access to products.
• Guidelines on pp. 447-455 (Chapter 12).
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Combination Layout
• Have one area for order picking with small amounts of fast moving products.
• Have another area for storage.
inbound
outbound
receiving
shipping
offices
Longer term storage
Longer term storage
Longer term storage
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Order Picking Strategies
• Minimize travel time/distance in warehouse to fill orders.
• Sequence items for single pass order picking.
• Zoning: Divide stock into separate zones for different pickers.
– Divide order into sub-orders for each zone.
• Batching: Collect several orders and fill in one pass.
• Interleaving: Replace stock and fill orders on same pass.