12存储和搬运决策和ASMS3000决策分析平台

存储与搬运决策StorageandHandlingDecisionsChapter12“Perfectionisnotattainable,butifwechaseperfection,wecatchexcellence.”VinceLombardiCR(2023)PrenticeHall,Inc.1产品计划三角形ProductinthePlanningTriangleCR(2023)PrenticeHall,Inc.PLANNINGORGANIZINGCONTROLLINGTransportStrategy•Transportfundamentals•TransportdecisionsCustomerservicegoals•Theproduct•Logisticsservice•Oc.&info.sys.InventoryStrategy•Forecasting•Inventorydecisions•Purchasingandsupplyschedulingdecisions•Storagefundamentals•StoragedecisionsLocationStrategy•Locationdecisions•Thenetworkplanningprocess计划组织控制TransportStrategy•Transportfundamentals•TransportdecisionsCustomerservicegoals•Theproduct•Logisticsservice•Oc.&info.sys.InventoryStrategy•Forecasting•Inventorydecisions•Purchasingandsupplyschedulingdecisions•Storagefundamentals•StoragedecisionsLocationStrategy•Locationdecisions•Thenetworkplanningprocess库存战略预测客户服务目标采购和供应时间决策存储基础知识存储决策产品物流服务订单管理和信息系统库存决策运输战略运输基础知识运输决策选址战略选址决策网络规划流程2Storage/HandlingDecisionsinInventoryStrategyPLANNINGORGANIZINGCONTROLLINGTransportStrategy•Transportfundamentals•TransportdecisionsCustomerservicegoals•Theproduct•Logisticsservice•Oc.&info.sys.InventoryStrategy•Forecasting•Inventorydecisions•Purchasingandsupplyschedulingdecisions•Storagefundamentals•StoragedecisionsLocationStrategy•Locationdecisions•ThenetworkplanningprocessPLANNINGORGANIZINGCONTROLLINGTransportStrategy•Transportfundamentals•TransportdecisionsCustomerservicegoals•Theproduct•Logisticsservice•Oc.&info.sys.InventoryStrategy•Forecasting•Inventorydecisions•Purchasingandsupplyschedulingdecisions•Storagefundamentals•Storage/handlingdecisionsLocationStrategy•Locationdecisions•ThenetworkplanningprocessCR(2023)PrenticeHall,Inc.3存储决策StorageDecisions12.1选址SiteSelection·

Findsaspecificrealestatesiteasastoragelocation·

Weightedchecklistisagoodapproach.Recall,FactorMarginalFactorsWeightsscoresscore125102919............124832

Weightedscore2864StorageDecisions(Cont’d)CR(2023)PrenticeHall,Inc.512.2设计与运作规划12.2.1确定设施的规模简单地说，规模是指仓库建筑的总容积——长、宽和高。1.无趋势规模确定问题2.有趋势规模确定3.对规模确定方法的评述6Spacerequirements,sq.ft.RentedspacePrivately-operatedspaceTimeMixedStrategyforWarehouseSpaceNeedforsomespaceisseasonalCR(2023)PrenticeHall,Inc.12-57DeterminationofaMixedWarehouseStrategyfora60,000sq.ft.Privately-OperatedWarehousePrivatespaceexceededCR(2023)PrenticeHall,Inc.8设备配置• 配置在一个高吞吐量的设备中影响处理成本，但不重要• 正方形或长方形的形状是最好的。L形的设计差，除非使用输送机。•对高吞吐量的设施单层设计是流行的，并且土地成本不太高9StorageDecisions(Cont’d)CR(2023)PrenticeHall,Inc.10空间布局在建筑物中配置储物架和过道空间布局影响建筑规模和尺寸站台布置由建筑物的侧边和需要的卡车数量决定11StorageDecisions(Cont’d)CR(2023)PrenticeHall,Inc.12设施评价FacilityEvaluation假设圣路易斯的某仓库考虑降低制造商和顾客之间的运输成本。目前的出货量直接来自纽约的制造商。在仓库有10美元/担的处理成本。DirectshipmentsCR(2023)PrenticeHall,Inc.13设施评价FacilityEvaluationSupposeapoolpointatSt.Louisisbeingconsideredtolowertransportationcostsbetweenmanufactureranditscustomers.Shipmentscurrentlyaremadedirectlyfromthemanufacturer’sinventoryinNewYork.Thereisa$10/cwt.handlingchargeatthepoolpoint.DirectshipmentsCR(2023)PrenticeHall,Inc.14FacilityEvaluation(Cont’d)ShipmentsthroughpoolpointNow,addhandlingcostof$10/cwt.400cwt.=$4,000foratotalcostof$15,472+4,000=$19,472.ConclusionNobenefittousingthepoolpoint.CR(2023)PrenticeHall,Inc.15WhenisaPoolPointLikelytobeanAdvantage?当装运规模小当需求短缺当运输的经济性是重要的当池点（中转库）的运营成本相对于运输成本比较低对服务而言，转运时间不重要CR(2023)PrenticeHall,Inc.16WhenisaPoolPointLikelytobeanAdvantage?WhenshipmentsizesaresmallWhendemandisfarfromsourcepointsWhentransportationrateeconomiesare significantWhenpoolpointoperatingcostsarelow relativetotransportationcostsWhentransfertimesareinsignificantto serviceCR(2023)PrenticeHall,Inc.1712.3物料搬运系统设计控制成本搬运通常是劳动密集型活动原则成本降低通过以下途径：减少搬运距离一次性处理单位数量增加一次订单，一次拣货提高储存密度18降低成本也可以通过以下活动实现：精心规划建筑物的物理布局订单置于分拣区自动化或者辅助机械取代人力通过计算机系统帮助计划建筑物内的工作流程19HandlingDecisionsCR(2023)PrenticeHall,Inc.20物料搬运系统选择管理层在确定物料搬运系统进行分析中，应考虑的问题：（1）外部的物料搬运系统（例如托盘的使用）（2）仓库设计对设备的选择限制（3）系统内货物性质和规模对设备选择的影响（4）货物的特性是系统选择的决定性因素（5）为了应付意外情况而留出的余地也会影响系统设计。21物料搬运系统选择确定因素：自动化水平托盘尺寸存储数量吞吐量水平产品特性应急计划金融分析处理系统的方案22HandlingDecisions(Cont’d)CR(2023)PrenticeHall,Inc.23产品布局的决策1.存货布局2.存货的排列3.库存定位法24存货布局的方法一、往返拣货二、拣货员制定路径三、指定每位工作人员的拣货区，拣货员在其工作区域内使用往返拣货或拣货员制定路径的方式进行拣货25HandlingDecisions(Cont’d)CR(2023)PrenticeHall,Inc.26体积-订单指数储存货物所需的平均空间（立方英尺）与该货物的日平均订单数量的比值。数值低的货物应尽可能靠近出货点放置。27HandlingDecisions(Cont’d)·

Cube-per-orderindex

·

Layoutexample

-

Bypopularity

-

Bycube

-

ByCPO

Thecube-per-orderindexistheratioofaproduct’saveragerequiredcubicfootageforstoragetotheaveragenumberofdailyordersonwhichtheitemisrequested.Theproductswiththelowestindexvaluearelocatednearesttheoutboundk.CR(2023)PrenticeHall,Inc.28

Product

(1)

ItemSize,

cu.ft.

(2)

Expected

Numberof

Orders/Yr.

(3)

Average

Inventory,

Units

(4)=(2)/250

Average

Number

ofDaily

Ordersa

(5)=(1)´(3)

Required

Storage

Space,

cu.ft.

(6)=(5)/(4)

Cube-

Per-Order

Index

A

6.0

6,750

800

27

4,800

177.8

B

4.0

15,750

16,000

63

64,000

1015.9

C

1.0

11,250

25,120

45

25,120

558.2

D

8.0

25,500

18,600

102

148,800

1458.8

E

3.0

17,750

12,533

71

37,599

529.6

F

5.0

3,500

3,936

14

19,680

1405.7

G

15.0

6,250

907

25

13,605

544.2

Totals

86,750

77,896

313,604

aBasedon250sellingdaysperyear

ProductLayoutExampleBasicdataBycubeByCPOBypopularityCR(2023)PrenticeHall,Inc.12-2929DDF,DDInboundraildockC,BB,FA,EE,G,CLayoutbyCPOLowestindexvaluesOutboundtruckkHighestindexvalues30活动分析布局按活动刻画法得出的一个高吞吐量仓库的区域布局高吞吐量的药品储存库的布局返品大宗散货促销商品保税货物整箱货散箱货收货31LayoutbyActivityProfilingDatamineorderstodetermineactivitydistributions.Layoutwarehousespaceaccordingtoactivitylevels.Ahigh-throughputwarehouselayoutfordrugstorereplenishment高吞吐量的药品储存库的布局3212.4订单-拣货操作提高搬运效率的订单处理

产品排序

拣货员分区订单分割货物批量处理

CR(2023)PrenticeHall,Inc.33HandlingDecisions(Cont’d)存储安排StockArrangement广场布局On-the-squarelayout角盘布局Angularpalletplacement

CR(2023)PrenticeHall,Inc.34HandlingDecisions(Cont’d)OrderhandlingforincreasedhandlingefficiencyProductsequencingonpickerlistPickerzoningandthe“bucketbrigade”OrdersplittingMultipleorderpickingperpickingpassStockArrangementOn-the-squarelayoutAngularpalletplacement

CR(2023)PrenticeHall,Inc.35(a)On-the-squarepalletplacementStoragebayCenterlineofaisle(b)

AngularpalletplacementStoragebayCenterlineofaislePalletLayoutinWarehousesTop-downviewofstoragebays36HandlingDecisions(Cont’d)IncreasescubeutilizationStockArrangement·

On-the-squarepalletlayout·

Angularpalletlayout存储定位识别法Stocklocator-identificationmethods·

固定定位器识别法Fixedlocator-identificationmethod·

随机定位识别方法Randomlocator-identificationmethod·

区域定位ZonelocationCR(2023)PrenticeHall,Inc.37HandlingDecisions(Cont’d)IncreasescubeutilizationStockArrangement·

On-the-squarepalletlayout·

AngularpalletlayoutStocklocator-identificationmethods·

Fixedlocator-identificationmethod·

Randomlocator-identificationmethod·

ZonelocationCR(2023)PrenticeHall,Inc.38EquipmentSelectionOne-timepurchaseofequipmentofdifferenttypescanbedecidedonbasisofpresentvalueanalysis,orbyselectingthealternativewiththelowestNPV.

where

NPV =netpresentvalueofequipmentoveritsusefullife($)

I =initialinvestment($)

C =annualoperatingcost($)

i =thediscount,orhurdle,ratethatsuchinvestments areexpectedtoreturn

Sn =salvagevalueinyearn($)

n =usefullifeoftheequipment(years)CR(2023)PrenticeHall,Inc.39EquipmentSelection(Cont’d)Problem

TwotypeAforklifttruckscandothesameworkasthreetypeBtrucks.Additionaldataare:CR(2023)PrenticeHall,Inc.40EquipmentSelection(Cont’d)SolutionSolvetheNPVequationforthetwoalternatives.FortrucktypeA,FortrucktypeB,ChoosetwotypeAtrucksCR(2023)PrenticeHall,Inc.41EquipmentReplacementAfinancialproblemAlternativesarecomparedthroughpresentvalue analysisTypicaldesignconcernsdifferingdegreesof automation,capacity,andequipmentlife.ExampleAforklifttruckthatcosts$3,000andrequires$200tooperateinitsfirstyear,butoperatingcostsincreaseattherateof$30peryearsquaredthereafter.Technologicalimprovementreducesoperatingcostsby$20peryear.Thenormallifeofatruckis10yearsandthetruckcanbesoldforitsremainingundepreciatedvalue.Adiscountrateof20%/yr.isused.Whenshouldthetruckbereplaced?Wecalculatetheequivalentannualcostaccordingto42Accumulatescostsforyears1and2

ReplacementExampleaComputedasCj=200-20(j-1)+30(j-1)2andaccumulatedwhenthereismore thanoneyearinthereplacementcyclebComputedasSn=I[1-0.1(n)]Replace-mentCycleTime,n(1)InitialInvest-ment,I(2)TotalOperatingCosts,Cj(3)DiscountedOperatingCosts,Cijjjn()11+=å(4)SalvageValue,Sn(5)DiscountedSalvageValue,Sinn()1+(6)DiscountFactor,iiinn()()111++-(7)=(1+3-5)(6)EquivalentAverageAnnualCost,ACn1$3,000$200a$167$2,700b$2,2501.20$1,10023,0004103122,4001,6680.651,06833,0006904752,1001,2150.471,06243,0001,1006721,8008680.391,09453,0001,7009131,5006030.331,09263,0002,5501,1981,2004020.301,13873,0003,7101,5229002510.281,19683,0005,2401,8786001400.261,23293,00