Jeff Gillett August, Demystifying 3D Load Configurator Setup and Use: A Guide for Getting Started

Transcription

1 Jeff Gillett August, 2014 Demystifying 3D Load Configurator Setup and Use: A Guide for Getting Started

2 Agenda 3D Load Configurator - Background Case Study Inbound Logistics Configuration Details Pitfalls Lessons Learned Questions and Answers 2

3 What is 3D Load Configurator? Designed to place objects into a container while considering Length, Width, and Height 3D Load Config also Considers: Product Orientation Stacking Compatibility Rules Loading Patterns by Compartment Improves Equipment Utilization 3

4 What is 3D Load Configurator? Provides a Three Dimensional Representation of the Trailer 4

5 Why Isn t It Used More Often? Some Common Reasons Given: Not Worth the Trouble Too Difficult to Setup Hard to Maintain It Doesn t Work 5

6 Are the Concerns Valid? Not Worth the Trouble: This is only true if ignoring the product orientation / stackability rules and possible freight savings is no issue for your organization Too Difficult to Setup: In recent versions many enhancements have strengthened the 3D Load Configurator product and made it easier to setup and use Hard to Maintain: If you are already maintaining items and ship unit information (as most of us are) then you are already doing most of required maintenance It Doesn t Work: Not True. As we will see it works quite well 6

7 Why Isn t It Used More Often? The OTM 3D Load Configurator is an undeniably powerful tool but can sometimes be intimidating to setup User don t always know where to begin It can be helpful to look at an example of a real-world application of this functionality 7

8 Agenda 3D Load Configurator - Background Case Study Inbound Logistics Configuration Details Pitfalls Lessons Learned Questions and Answers 8

9 Case Study Inbound Logistics Global Third Party Logistics Provider Serving the Automotive Industry Setup and leveraged this technology in their Inbound Freight Model Multiple Suppliers Single Delivery Location 9

10 Case Study Inbound Logistics Identified a need to fully utilize inbound trailer space to limit the number of inbound shipments and shift mode from multiple LTL or ½ full truckloads, to fewer, fuller truckloads Need more precise estimation of product cube Without 3D Load Config: OTM assumes it can stack from floor to ceiling No adherence to stackability constraints or stacking limits No 3D picture of the trailer to see stacking results 10

11 Case Study Inbound Logistics Brake Lines are a Major Category of their Inbound Supplies Brake Lines are Long and Thin 16 pallets that are built around the brake lines at time of shipping Up to 14,400 Brake Lines can occupy just 1 pallet space in a trailer 11

12 Case Study Inbound Logistics Stackability Rules are Key!! Any Brake Line part number can stack on top of any other brake line part number Brake Lines can stack on top of any other auto parts Non-brake lines (all other auto parts being shipped) can NOT stack on top of Brake Lines All other parts (non brake lines) are free to stack on top of or below each other Brake Lines can stack from floor to ceiling. 12

13 The Solution Implement OTM s 3D Load Configurator Use Stacking Compatibility to enforce Brake Line Stacking Rules Maintain Ship Unit Dimensions to Estimate Product Cube Use 3D Trailer Representations to Better Understand how OTM is utilizing Trailer Space 13

14 Agenda 3D Load Configurator - Background Case Study Inbound Logistics Configuration Details Pitfalls Lessons Learned Questions and Answers 14

15 Configuration Details Data Relationship Parameter Set Changes Transportation Handling Units / THU Profiles Ship Unit Specs Load Configuration Setup Load Configuration Rule Stacking Compatibility Packaged Item Details Equipment Group Dimensions Cortona Viewer Results 15

16 Data Relationship We used a 3-step approach For Example: The Packaged Item is a box containing 50 rear view mirrors 16

17 Data Relationship 100 shipping boxes go onto a 40x48 pallet The pallet is our Transport Handling Unit 17

18 Data Relationship 26 Pallets can fit into a 53 Trailer The Trailer is our Equipment Group 18

19 Parameter Set Changes Make a copy of your existing Planning Parameter Set In the Container Optimization section create a CONTAINER OPT CONFIG ID for 3D Load Config 19

20 Parameter Set Changes You can alter the parameter settings any number of different ways depending on the desired behavior During testing you can adjust these and fine tune the solution You must mark the USE 3D BASED LOAD CONFIGURATION value as TRUE 20

21 Transportation Handling Units / THU Profiles The THU Profile is made up of one or more Transport Handling Units 21

22 Transportation Handling Units / THU Profiles The THU itself defines the dimensions of the pallet One of the THU s we created was the Brake Line THU In this case it is 192 (length) x 40 (width). We are assuming these can stack 9 ft high the max height of the trailer 22

23 Ship Unit Specifications In addition to THU s, we needed Ship Unit Specifications that will later be applied to our Packaged Items. We need two major categories: STACK Indicating NON Brake Line parts that can stack on top of each other NON-STACK Indicating Brake Line parts that can not be stacked upon (except by each other). 23

24 Load Configuration Setup The Load Configuration Setup page allows you to control how packaged items are handled during the planning process. The setup information will be used when you configure Load Configuration rules. 24

25 Load Configuration Setup In our case we have defined two configuration setups: STACK (non Brake Line items) and NON_STACK (for Brake Lines). STACK setup includes a Stacking Layers total of 3. 25

26 Load Configuration Setup NON_STACK has no Stacking Layer restriction. This is because we want brake Lines to be able to stack as high as the trailer dimension allows. 26

27 Load Configuration Rule The load configuration rule helps to determine which load configuration setup to match to your requirements. In our case we will need only two: STACK and NON_STACK. This rule simply says if the Packaging Unit is STACK, use the load config setup ID of STACK that we created. 27

28 Load Configuration Rule Similarly, if the rule is NON_STACK, use the NON_STACK load config setup. The Packaging Unit will be applied to the Packaged Items. In this way the item being shipped will determine which of the load configuration setups will be used. 28

29 Stacking Compatibility The stacking compatibility rules determine what THUs or Packaging Items can stack on top of what. One of our rules is Brake Lines can stack on top of other Brake Lines. To enforce this rule a stacking compatibility was created. The rule says if PALLET_192x40 (the brakeline THU) is the bottom THU, then anything that is NON_STACK (a Brake Line) can be placed on top. In other words, Brake Lines can stack on top of Brake Lines. Note the Stackable box is checked. If this were left unchecked it would mean the two things are not compatible. 29

30 Stacking Compatibility Here we see how we prevent other items from stacking on top of Brake Lines. This shows if PALLET_192x40 is the bottom THU, nothing with STACK can be placed on top. In other words non Brake Lines can NOT stack on top of Brake Lines. The Stackable box is unchecked so the relationship described in this rule is disallowed. 30

31 Packaged Item Details The Packaged Items store information about the weight, volume, and dimensions of the goods being shipped. They also contain the THU Profile IDs. 31

32 Packaged Item Details The Ti / High section provides the details of how high, how many tiers, can be stacked for the given item and how many units are in a given layer. 32

33 Equipment Group Dimensions Equipment Groups will need to contain internal dimensions. This will allow OTM to calculate the amount of space within the equipment groups that is being taken by the various packaging units. 33

34 Cortona Viewer You will need a Cortona Viewer that is compatible with your browser in order to see the visual 3D representation OTM will create. A free download is available and licenses can be purchased from Cortona. 34

35 Results The stacking rules are being honored: The long Brake Line parts can stack on top of each other The smaller, Non-Brake Line parts can stack on top of each other The Non-Brake Lines can NOT stack on top of Brake Lines 35

36 Results 3D Load Configurator allows us to see how the goods are being placed in the trailer in OTM s planning logic. 36

37 Results The tool allows you to visually load and unload products in the trailer 37

38 Results OTM will even play a simulation where it shows the packages loading into the trailer to further demonstrate the stacking pattern and rules that were considered. 38

39 Agenda 3D Load Configurator - Background Case Study Inbound Logistics Configuration Details Pitfalls Lessons Learned Questions and Answers 39

40 Pitfalls Bad or Missing Data Packaged Item Data is Critical If Data is Missing or Inaccurate the Load Configurator will Not Work or Will Give Poor Results. Garbage In = Garbage Out Poorly Defined Requirements Cause Delays and Re-Work 40

41 Agenda 3D Load Configurator - Background Case Study Inbound Logistics Configuration Details Pitfalls Lessons Learned Questions and Answers 41

42 Lessons Learned Plan to implement 3D Load Configurator as a separate phase of the overall OTM implementation or as a separate project unto itself Get your data loaded as early in the process as you can Leave time for testing 3D Load Configurator definitely will require some trial and error 42

43 Lessons Learned Make the 3D planning parameter set your default or have one planning parameter set for 3D planning and a separate set for planning that does not require load configurator Don t forget your Equipment Group Dimensions it won t work without these, even if everything else is loaded correctly Have Fun! It s a good feeling when you see that first trailer display properly in OTM 43

44 Agenda 3D Load Configurator - Background Case Study Inbound Logistics Configuration Details Pitfalls Lessons Learned Questions and Answers 44

45 Questions and Answers 45

46 About Capgemini With around 120,000 people in 40 countries, Capgemini is one of the world's foremost providers of consulting, technology and outsourcing services. The Group reported 2011 global revenues of EUR 9.7 billion (approximately $13.5 billion USD). Together with its clients, Capgemini creates and delivers business and technology solutions that fit their needs and drive the results they want. A deeply multicultural organization, Capgemini has developed its own way of working, the Collaborative Business Experience TM, and draws on Rightshore, its worldwide delivery model. Rightshore is a trademark belonging to Capgemini The information contained in this presentation is proprietary Capgemini. All rights reserved.