New tool for aiding warehouse design process Presented by: Claudia Chackelson, Ander Errasti y Javier Santos
Outline Introduction validation
validation Introduction Warehouses play a key role in supply chain effectiveness.
validation Introduction Nowadays, warehouse design has become more complex. Pick More Orders With Store More Items Less With Lead time Add More Value Less Errors
validation Introduction High number of possibilities and strong interactions between variables The process leading to the identification of the specific solutions is not clear. There is considerable reliance on the experience of individual warehouse designers. Deciding the TOOLS to be used Making JUDGMENTS between VARIOUS ALTERNATIVE SOLUTIONS
validation Introduction The most complex task when designing warehouses is: To select one of the thousands of feasible design solutions This work proposes a graphic tool for aiding warehouse design process, helping managers to visualize, select and evaluate different alternatives.
validation Prepare possible layouts (warehouse zones). Define storage systems. Level of automation. Storage. Material handling. Determine operating procedures and methods. Receiving. Put-away. Storage. Order picking. Shipping.
validation To reveal warehouse design opportunities, the Warehouse Activity Profiling needs to be measure (Frazelle. 2002). Storage unit vs. receiving and shipping units. Zoning criteria (family, client, value, temperature, chemical, activity). Lines per order. Volume per order. Storage unit inventory. Storage unit.
validation Warehouse Design Alternatives Diagram The design alternatives related to preparing possible layouts, considering possible types and characteristics, and determining operating procedures and methods have been restructured in a star-shaped tool. Logic reception/ Reading INTERNAL Own handling Rented handling Physic reception Artificial vision (Packing list) EXTERNAL Logic shipping / Reading Artificial vision Reception (Packing list) INTERNAL EXTERNAL Own handling Rented handling NO SOFTWARE WITH BASIC SOFTWARE (volume and loading pattern ) WITH ADVANCE Loading SOFTWARE (loading Pattern sequence and unloading time) Docks and zones scheduling STORAGE Physic shipping CROSS-DOCKING by order (NO STOCK AND NO MANIPULATION) CROSS-DOCKING by article (NO STOCK BUT WITH MANIPULATION) RECEPTION INDEPENDENT COMBINED DOCK AND ZONES Balanced docks and zones Balanced and workers SHIPPING INDEPENDENT Shipping (Packing list) Internal External SUPPLIER (direct logistic) Stock-holding Artificial vision INFORMATIC CROSS-DOCKING by order (NO STOCK AND NO MANIPULATION) CROSS-DOCKING by article (NO STOCK BUT WITH MANIPULATION) Product Package CLIENT (reverse logistic) (electronic EDI) PRE-RECEPTION Order data exchange Origin and type of product Stock-holding Mono-destination STORAGE Multi-destination LESS-THAN- CONTAINER LOAD FULL TRACK Track load type (Packing list) Artificial vision INFORMATIC (electronic EDI) PRE-RECEPTION Order data exchange Stock control Automation Level PARTS TO PICKER AS/RS Miniload VLM Carrousel Shuttles PICKER TO PARTS Conventional Narrow aisle Push-back Dynamic Continuous Periodic Put-away Automation Level Routing OPTIMAL PARTS TO PICKER AS/RS S-shape SKUs Miniload Return VLM Mid-point REPACKAGING NEEDED Carrousel Largest-gap Worker zone Shuttles Combined SAME SKU FOR assignment PICKER TO PARTS HEURISTICS RECEPTION AND Conventional STORAGE Narrow aisle Push-back Dynamic ONE ZONE Pallet truck One worker Hand truck Reach trucks Various Pallet jack Counterbalanced lift trucks Waking stacker Order picker INTERNAL WALKING VEHICLES EXTERNAL Compact shuttle AGVs RIDING VEHICLES Conveyors Own handling DIRECT Cranes AUTOMATED VEHICLES Full Rented handling NO ½ SKUs TECHNOLOGY DISCRETE Handling ¼ AIDED PALLET DIRECTED Search and TECHNOLOGY AIDED Put-to-light CONTINUOUS CONTAINER verify location RFID PUT-AWAY BOX INDEPENDENT KIT (single command) Put-away Order release principles UNIT Families mode Turnovers JOINT PUT-AWAY AND Safety PICKING (dual or UNIQUE ZONE FORWARD Clients multiple command) PICK AREA CLASS-BASED DEDICATED PICKING CLOSEST OPEN LOCATION Zoning INDEPENDENT RANDOM (single command) Automation Level Storage FAMILY GROUPING FEFO, LIFO, FIFO criterion CLASS-BASED PARTS TO PICKER Clients Routing AS/RS COI volume Miniload S-shape OPTIMAL Turnovers VLM Return Diagonal Storage strategy Semicircle Worker zone Carrousel Mid-point Within-aisle assignment Shuttles Largest-gap Across-aisle Combined PICKER TO PARTS Conventional HEURISTICS Narrow aisle REPACKAGING Push-back NEEDED ONE ZONE SKUs Dynamic SAME SKU FOR STORAGE One worker AND SHIPPING Various Discrete replenishment Continuous replenishment Organizational and Operating UNIQUE Picking zone Policies INTERNAL STORAGE AND without storage EXTERNAL PICKING ZONE Picking zone Hand truck with storage System Characteristics and Own handling Pallet jack Technology Level FORWARD PICK AREA Waking stacker Rented handling NO WALKING VEHICLES Shared Decisions Put-away TECHNOLOGY BY ORDER Picking Pallet truck Storage - Picking AIDED zoning DISCRETE Reach trucks TECHNOLOGY AIDED BY ZONE Counterbalanced lift trucks Search and Shared Decisions Reception - Pick-to-light Order picker verify location Pick-to-voice Shipping CONTINUOUS Compact shuttle BY ARTICLE RIDING VEHICLES Pick-and-pass Pick-and-sort AGVs Sort-while-pick Conveyors Batching and Navigation picking system Cranes AUTOMATED VEHICLES sorting Order release mode Handling Commands Order Picking
validation Warehouse Design Alternatives Diagram This format has been selected because it allows the simultaneous visualization of several design alternatives, as well as the comparison of different design configurations. Logic reception/ Reading INTERNAL Own handling Rented handling Physic reception Artificial vision (Packing list) EXTERNAL Logic shipping / Reading Artificial vision Reception (Packing list) INTERNAL EXTERNAL Own handling Rented handling NO SOFTWARE WITH BASIC SOFTWARE (volume and loading pattern ) WITH ADVANCE Loading SOFTWARE (loading Pattern sequence and unloading time) Docks and zones scheduling STORAGE Physic shipping CROSS-DOCKING by order (NO STOCK AND NO MANIPULATION) CROSS-DOCKING by article (NO STOCK BUT WITH MANIPULATION) RECEPTION INDEPENDENT COMBINED DOCK AND ZONES Balanced docks and zones Balanced and workers SHIPPING INDEPENDENT Shipping (Packing list) Internal External SUPPLIER (direct logistic) Stock-holding Artificial vision INFORMATIC CROSS-DOCKING by order (NO STOCK AND NO MANIPULATION) CROSS-DOCKING by article (NO STOCK BUT WITH MANIPULATION) Product Package CLIENT (reverse logistic) (electronic EDI) PRE-RECEPTION Order data exchange Origin and type of product Stock-holding Mono-destination STORAGE Multi-destination LESS-THAN- CONTAINER LOAD FULL TRACK Track load type (Packing list) Artificial vision INFORMATIC (electronic EDI) PRE-RECEPTION Order data exchange Stock control Automation Level PARTS TO PICKER AS/RS Miniload VLM Carrousel Shuttles PICKER TO PARTS Conventional Narrow aisle Push-back Dynamic Continuous Periodic Put-away Automation Level Routing OPTIMAL PARTS TO PICKER AS/RS S-shape SKUs Miniload Return VLM Mid-point REPACKAGING NEEDED Carrousel Largest-gap Worker zone Shuttles Combined SAME SKU FOR assignment PICKER TO PARTS HEURISTICS RECEPTION AND Conventional STORAGE Narrow aisle Push-back Dynamic ONE ZONE Pallet truck One worker Hand truck Reach trucks Various Pallet jack Counterbalanced lift trucks Waking stacker Order picker INTERNAL WALKING VEHICLES EXTERNAL Compact shuttle AGVs RIDING VEHICLES Conveyors Own handling DIRECT Cranes AUTOMATED VEHICLES Full Rented handling NO ½ SKUs TECHNOLOGY DISCRETE Handling ¼ AIDED PALLET DIRECTED Search and TECHNOLOGY AIDED Put-to-light CONTINUOUS CONTAINER verify location RFID PUT-AWAY BOX INDEPENDENT KIT (single command) Put-away Order release principles UNIT Families mode Turnovers JOINT PUT-AWAY AND Safety PICKING (dual or UNIQUE ZONE FORWARD Clients multiple command) PICK AREA CLASS-BASED DEDICATED PICKING CLOSEST OPEN LOCATION Zoning INDEPENDENT RANDOM (single command) Automation Level Storage FAMILY GROUPING FEFO, LIFO, FIFO criterion CLASS-BASED PARTS TO PICKER Clients Routing AS/RS COI volume Miniload S-shape OPTIMAL Turnovers VLM Return Diagonal Storage strategy Semicircle Worker zone Carrousel Mid-point Within-aisle assignment Shuttles Largest-gap Across-aisle Combined PICKER TO PARTS Conventional HEURISTICS Narrow aisle REPACKAGING Push-back NEEDED ONE ZONE SKUs Dynamic SAME SKU FOR STORAGE One worker AND SHIPPING Various Discrete replenishment Continuous replenishment Organizational and Operating UNIQUE Picking zone Policies INTERNAL STORAGE AND without storage EXTERNAL PICKING ZONE Picking zone Hand truck with storage System Characteristics and Own handling Pallet jack Technology Level FORWARD PICK AREA Waking stacker Rented handling NO WALKING VEHICLES Shared Decisions Put-away TECHNOLOGY BY ORDER Picking Pallet truck Storage - Picking AIDED zoning DISCRETE Reach trucks TECHNOLOGY AIDED BY ZONE Counterbalanced lift trucks Search and Shared Decisions Reception - Pick-to-light Order picker verify location Pick-to-voice Shipping CONTINUOUS Compact shuttle BY ARTICLE RIDING VEHICLES Pick-and-pass Pick-and-sort AGVs Sort-while-pick Conveyors Batching and Navigation picking system Cranes AUTOMATED VEHICLES sorting Order release mode Handling Commands Order Picking
validation Warehouse Design Alternatives Diagram rigin and type f product Automation Level Storage Outsourcin This format has been selected because it allows the simultaneous visualization of several design alternatives, as well as the comparison of different design configurations. Stock control PARTS TO PICKER AS/RS Miniload VLM Carrousel Shuttles Continuous Periodic PICKER TO PARTS Conventional Narrow aisle Push-back Dynamic UNIT DEDICATED CONTAINER BOX UNIQUE ZONE CLOSEST OPEN LOCATION RANDOM KIT Full ½ ¼ PALLET FORWARD PICK AREA SKUs Families Turnovers Safety Clients CLASS-BASED Zoning Search and verify loca FAMILY GROUPING FEFO, LIFO, FIFO criterion holding CLASS-BASED Clients COI volume Turnovers Diagonal Storage strategy Semicircle Within-aisle Across-aisle Worker zon assignment
validation validation Delphi method Iterative process used to collect the judgments of experts using questionnaires with feedback (Skulmoski et al. 2007). 10 Experts with: Knowledge and experience Capacity and willingness to participate Enough time to participate Effective communication skills
validation validation A two-round-questionnaire was needed in order to reach consensus. Questionnaires were oriented to: improve and adequacy verify order and clarity of the concepts include missing alternatives.
validation Warehouse Design Alternatives Diagram is useful to: visualize design alternatives identify shared decisions identify redesign opportunities However, the main objective is to support: warehouse design alternative selection alternative evaluation
validation Classification according to complexity To identify the necessity of defining multiple zones Lines per day Items per line Storage unit inventory Storage unit Less than 100 Less than 10 Less than 100 Units or small items 100-1000 10-50 100-1000 Cases More than 1000 More than 50 More than 1000 Pallets
validation Guideline during design process To develop a record of high-performance design solutions: Experts were asked to collaborate by providing design solutions that could be catalogued as best practices. These solutions were classified based on complexity.
Pick and pass Pick and sort Sort while pick Navigation picking system Replenishment continuous or discrete Introduction validation Complexity Lines per order: 100-1000 Volume per order: less than 10 items per order Storage unit inventory: 483 make to stock items Storage unit: Pallets Reception Put-away Design Solution Performance measure INTERNAL Own handling Rented handling Physic reception INTERNAL TRUCK DRIVER Physic shipping Technology Level PARTS TO Technology Level TRUCK DRIVER RFID Passive Active BAR CODE Item Load EXTERNAL TO PARTS AIDED BY SOFTWARE BAR CODE EXTERNAL PARTS TO EASY TO UNLOAD Dock and zone scheduling Shipping Automation Level Routing Stock-holding HEURISTICS AUTOMATED S-Shape Return PARTS TO Mid-point SKUs AS/RS AVS/RS DIFFERENT UNITS STORAGE Miniload Largest-gap FOR RECEPTION VLM Combined AND STORAGE Worker Carousel zone CROSS-DOCKING TO PARTS OPTIMAL SAME UNITS FOR By article assignment RECEPTION AND Conventional STORAGE By order Narrow aisle Push-back Dynamic Storage ONE ZONE One worker Hand truck Pallet truck Various Pallet jack Reach trucks Walking stacker Automation Level Counterbalanced lift truck CONTROL INTERNAL EXTERNAL WALKING VEHICLES Order pickers (packing list) Compact Shuttle Own handling RIDING VEHICLES AGVs READING AUTOMATED Storage Conveyors MECHANIZED Rented handling NO Cranes SKUs (Arch reading) TECHNOLOGY DISCRETE AUTOMATED VEHICLES PARTS TO AIDED DIRECTED RECEPTION PRE-RECEPTION AS/RS AVS/RS Handling PALLET INTEPENDENT (Control by Miniload TECHNOLOGY AIDED supplier) VLM Technology To search location CONTINUOUS Carousel Level To verify location and CASE quantity PUT-AWAY Put-away Logic TO PARTS Family grouping INDEPENDENT Conventional principles reception Turnovers Order By order Narrow aisle UNIT Value release By zone Push-back Clients By article Dynamic FORWARD PICK mode BASED ON COMBINED UNIQUE ZONE AREA CLASS-BASED COMBINED PUT- DOCK AND Storage STRATEGY AWAY AND PICKING ZONES DEDICATED RANDOM WALKING VEHICLES (Interleaving and Balance docks and strategy CLASS-BASED Hand truck zones Family grouping Continuous moves) Pallet jack Zoning Balance s Turnovers By order Walking stacker By zone and workers Value Clients RIDING VEHICLES By article Pallet truck Automation Level and Reach trucks PICKING Order pickers Logical Picking INDEPENDENT By order Compact Shuttle AUTOMATED By zone Counterbalanced lift truck SHIPPING By article AUTOMATED VEHICLES INTEPENDENT PARTS TO PICKER AGVs AS/RS AVS/RS Conveyors SKUs Miniload Handling Cranes VLM Carousel DIFFERENT UNITS Worker PICKER TO PARTS FOR STORAGE AND zone Conventional SHIPPING assignment Narrow aisle SAME UNITS FOR Push-back MULTI ZONE STORAGE AND Picking zone Progressive Dynamic SHIPPING without storage Synchronized ONE ZONE UNIQUE Picking zone STORAGE One worker Stock-holding STORAGE AND with storage Organizational and Operating Various PICKING ZONE Policies FORWARD PICK INTERNAL EXTERNAL Hand truck ZONE Stock-holding Pallet jack System Characteristics and and storage CONTROL Technology Level Own handling Walking stacker WALKING VEHICLES strategy (packing list) Rented handling NO TECHNOLOGY Shared Decisions Put-away, DISCRETE AIDED OPTIMAL Pallet truck Storage and Order picking Reach trucks READING TECHNOLOGY AIDED Order pickers Pick to light Compact Shuttle CONTINUOUS MECHANIZED Shared Decisions Reception and Technology Pick to voice HEURISTICS Counterbalanced lift truck (Arch reading) Shipping Level Put to light S-Shape RIDING VEHICLES Return PRE-RECEPTION AGVs Mid-point (Control client Order Conveyors Largest-gap order) Cranes release Combined AUTOMATED VEHICLES mode Logic Handling shipping Routing Quality: 99% Perfect Orders Productivity: 50-55 lines/hour/worker Storage or cross-dock Batching Order Picking
validation Warehouse design alternatives were restructured in star-shaped tool Warehouse Design Alternatives Diagram Delphi method helped to improve and validate it, guaranteeing its practical.
validation High-performance design solutions were: gathered using Warehouse Design Alternatives Diagram. classified according to complexity. Guideline that enriches the experience of a single practitioner with the experience of experts.
validation Future work will look for adding new design solutions: not addressed complexity s. Include new technological advances. more productive operating procedures and methods. Main objective: To guide practitioners, no matter which of complexity presents the warehouse they plan to (re)design.
New tool for aiding warehouse design process Thank you for your attention.