identify location for multi-facility regional distribution center
DESCRIPTION
Identify location for multi-facility regional distribution center. December 3, 2009 Team Kim H. Milton Stewart School of Industrial and Systems Engineering Georgia Institute of Technology. Agenda. I. Initiate > Project Members. Hamilton Sundstrand Project Representative - PowerPoint PPT PresentationTRANSCRIPT
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No part of it may be circulated, quoted, or reproduced for distribution outside without prior written approval from Hamilton Sundstrand and Team Kim
ISyE 6203 Term Project
December 3, 2009
Team KimH. Milton Stewart School of Industrial and Systems EngineeringGeorgia Institute of Technology
Identify location for multi-facility regional distribution center
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Agenda
I InitiateII AnalyzeIII EnvisionIV DesignV RecommendationVI Appendix
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I. Initiate > Project Members
Hamilton Sundstrand Project Representative
Dang Huynh – Global Logistics Manager Marc A. Bartos – Global Logistics Analyst
ISYE 6203 Project Group ‘Team Kim’
Hangil Kim Prabhkar N Navjyot Kaur Youngbin Park Jungbin Yim
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I. Initiate > Project TimelineOverall Preview for what we have done and where are we, and what we are going to do
Project Objectives & Goals
Project Timeline Best practice
benchmark
Initiate Analyze Envision
W1 W2 W3 W4 W5 W6 W7 W8 W9 W10
Project Assignment
Design
Class Presentation
Design Detailed To-Be Structure
Possible Scenarios
Future Scope
Find optimal consolidation schedule and location
Sensitivity Analysis
Gaining reliable data Consolidation
Methodology Net benefit calculation
Hamilton Sundstrand: 1. Have bi-weekly conference call (or E-mail) if needed 2. Report Status - four conference calls so far, fifth one is scheduled on Nov. 13th
- three presentations delivered so far Quality Assurance: Dr. John Vande Vate
Final Delivery1st
Conference Call2nd
Conference Call3rd
Conference Call4th
Conference Call
5thConference
Call(scheduled)
Timely Communication
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Agenda
I InitiateII RecommendationIII AnalyzeIV EnvisionV DesignVI Appendix
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II. Recommendation > Result
10%
90%
Shipment wt. for other routesShipment wt. for frequent routes
Ship all shipments on the following routes on
Wednesday and Friday
• SINGAPORE,ROCKFORD-Singapore• CO CLARE,MIRAMAR-Ireland• SINGAPORE,WEST HARTFORD-Singapore• WOLVERHAMPTON,SAN DIEGO-England• HALEY,ROCKFORD-Canada• FRACC IND B JUAREZ QUERETARO,SAN DIEGO-Mexico• LAVAL,ROCKFORD-Canada• SAINT-LAURENT,WINDSOR LOCKS-CANADA• HAMBURG,SAN DIEGO-Germany• RENFREW,SAN DIEGO-Canada• ZHUZHOU,SAN DIEGO-China
Top 11 frequent routes
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In top 11 frequent routes,
No. of Vendors on these routes: 22No. of Hamilton Sundstrand Co. on the routes: 7
II. Recommendation > Route Composition
04080
120160
Total
Total
# of shipments
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II. Recommendation > Implementation RecommendationIn top 11 frequent routes,
There are 7 routes that only have a single supplier
– RENFREW,SAN DIEGO HALEY INDUSTRIES– ZHUZHOU,SAN DIEGO ZHUZHOU SOUTH AEROENGINE – HAMBURG,SAN DIEGO LUFTHANSA TECHNIK LOGISTIK (DE) – FRACC IND B JUAREZ QUERETARO,SAN DIEGO TURBORREACTORES SA DE
CV– WOLVERHAMPTON,SAN DIEGO HS MARSTON AEROSPACE – CO CLARE,MIRAMAR Hamilton Sundstrand – HALEY,ROCKFORD HALEY INDUSTRIES
Single supplier routes
Can be implemented right away!
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II. Recommendation > Detailed Implementation
– LAVAL,ROCKFORD- Canada– HAMBURG,SAN DIEGO-Germany – COCLARE,MIRAMAR-Ireland– SINGAPORE,ROCKFORD– SINGAPORE,WEST- HARTFORD-Sin-
gapore
Routes run by DHL USA Inc.– SAINT-LAURENT, WINDSOR LOCKS-
Canada– HALEY,ROCKFORD-Canada– RENFREW,SAN DIEGO-Canada– LAVAL,ROCKFORD-canada– SINGAPORE,ROCKFORD-Singapore– SINGAPORE,WEST- HARTFORD-Singapore
Routes run by UPS SPS– WOLVERHAMPTON,SAN DIEGO
– HAMBURG,SAN DIEGO
– FRACC IND B JUAREZ QUERETARO,SAN DIEGO
– SAINT-LAURENT, WINDSOR LOCKS
Routes run by FedEx corp.
Possible Routes Consolidated
• WOLVERHAMPTON,SAN DIEGO -England• HAMBURG,SAN DIEGO-Germany• COCLARE,MIRAMAR-Ireland• FRACC IND B JUAREZ QUERETARO,SAN DIEGO
Consolidate by DHL USA Inc.• SAINT-LAURENT, WINDSOR LOCKS-Canada• HALEY,ROCKFORD-Canada• RENFREW,SAN DIEGO-Canada• LAVAL,ROCKFORD-Canada• SINGAPORE,ROCKFORD-Singapore• SINGAPORE,WEST- HARTFORD-Singapore
Consolidate by UPS SCS
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European carrier consoli-dation Canada carrier consolidation
DHL USA INC UPS SCS
II. Recommendation > Carrier Composition
33.134
65.304
1.250 0.009 0.227 0.008 0.069
FEDERAL EXPRESS CORP DHL EXPRESS USA INCUPS SUPPLY CHAIN SOLUTIONS INC DSV AIR AND SEA INCEXPEDITORS INTL EAGLE GLOBAL LOGISTICBAX GLOBAL EAGLE GLOBAL BROKERAGE
CEVA LOG CEVA FREIGHT
EXPEDITORS INTL
IMMEDIATE WORLDWIDE TRANSPORTATION
EMO TRANS INTER-NATIONAL FREIGHT
EAGLE GLOBAL LOGISTIC
DHL EXPRESS USA INC
BAX GLOBAL
FEDERAL EXPRESS CORP
SCHENKER INC
UPS SUPPLY CHAIN SO-LUTIONS INC
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II. Recommendation > Carrier CompositionReduction in Transportation
Cost Reduction in No. of Shipments
Reduction in CBF, MPF
Original number of shipments
Shipments after New schedule
0
500
1000
1500
2000
2500
Current Wed-Fri Shipment
# of shipment
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Agenda
I InitiateII RecommendationIII AnalyzeIV EnvisionV DesignVI Appendix
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III. AnalyzeWe analyze data with this procedure. In this phase, we firstly validate the raw data and make the basic consolidation model based on Hamilton Sundstrand’s suggestion
Initiate Analyze Envision Design
ComparingNet Benefit
of Consolidation
3Gaining Reliable Data
1 Developing Basic Consolidation
Model
2
Initiate Analyze EnvisionInitiate Analyze
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III. Analyze > 1. Gain Reliable Data
Regularize the data1-1
14
Shipper CompanyBOMBARIDER AEROSPACE
BOWMILL ENGRBOWMILL ENGR
BRADKENBRADKENBRADKENBRADKEN
BRUSSELS AIRLINES NV-SABRUSSELS AIRLINES NV-SA
…BRUSSELS AIRLINES NV-SA
C & D AEROSPACE CANADA COC &D AEROSPACE CANADA CO
Shipper CompanyBOMBARDIER AEROSPACE
BOWMILL ENGRBOWMILL ENGR
BRADKENBRADKENBRADKENBRADKEN
C&D AEROSPACE CANADA CO
C&D AEROSPACE CANADA CO
1. Delete Airlines 2. Identify
Names (Correct Typo)
Delete data whose supplier is Airline Emergency orders
(Mostly for repairs) Infrequent
shipments
Will be used for Macro
The raw data provided by HS had problems of the reliability - typos, lack of informa-tion, and weak linkages between files. Therefore, we cleaned raw data by following steps
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III. Analyze > 1. Gain Reliable Data
Clean up the data1-2
JMR, DGF (Carriers’ Data)
Bill Numbe
rWeight, Pieces
Vessel Name
Supplier
Country Export
Total Duty/ Fee
…
- DGF: 6,632 lines / JMR: 5,187 lines- Delete data which are not matched with ‘USD YTD’ data- Delete data whose supplier is Airline
Reliable Data DGF: 2,388 lines JMR: 3,028 lines
Will be used to get Current # of
Shipments Total Duty & Fees
before and after Con-solidation
: Duty + Custom’s Brokerage Fee
: Supplier Identifier with US YTD
The raw data provided by HS had problems of the reliability - typos, lack of information, and weak linkages between files. Therefore, we cleaned raw data by following steps
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III. Analyze > 1. Gain Reliable Data
Clean up the data (Cont.)1-2
US YTD (HS’s Data)
…
- YTD: 4,036 lines- Delete data whose supplier is Airline
Reliable Data US YTD: 4,013 lines
Will be used to get Latitude & Longtitude
of Suppliers/Consignees
Traffic Route
: Custom’s Brokerage Fee: Supplier Identifier with DGF/JMR
Carrier
NameClient ID
Shipper
Name Shipper Address
Shipper City
Shipper Zip
codeConsignee Address
The raw data provided by HS had problems of the reliability - typos, lack of informa-tion, and weak linkages between files. Therefore, we cleaned raw data by following steps
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III. Analyze > 2. Develop Basic Consolidation Model
As-Is To-Be
Understand HS’s Basic Consolidation Concept2-1
As-Is To-Be
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Visu
al B
asic
for
Exce
l Mac
ro
III. Analyze > 2. Develop Basic Consolidation ModelWe run the Excel Macro to calculate the reduced number of shipment according to one to seven days consolidation strategy of identical supplier, country of origin and date of shipment
Supplier Name Country of Origin Date of ShipmentIndex
233268293313314332338340365366367369412428430449450451524525530
A J WALTERS AVIATIONA J WALTERS AVIATIONA J WALTERS AVIATIONA J WALTERS AVIATIONA J WALTERS AVIATIONA J WALTERS AVIATIONA J WALTERS AVIATIONA J WALTERS AVIATIONA J WALTERS AVIATIONA J WALTERS AVIATIONA J WALTERS AVIATIONA J WALTERS AVIATIONA J WALTERS AVIATIONA J WALTERS AVIATIONA J WALTERS AVIATIONA J WALTERS AVIATIONA J WALTERS AVIATIONA J WALTERS AVIATIONA J WALTERS AVIATIONA J WALTERS AVIATIONA J WALTERS AVIATION
CACACACACACACACACACACACACACACAGBGBGBGBGBGB
09-Jan-0909-Jan-0912-Jan-0913-Jan-0913-Jan-0914-Jan-0914-Jan-0915-Jan-0915-Jan-0915-Jan-0915-Jan-0916-Jan-0920-Jan-0921-Jan-0921-Jan-0922-Jan-0922-Jan-0922-Jan-0928-Jan-0928-Jan-0929-Jan-09
268
314
338
367367367
430
451451
525
531
Consol.Index
ShipmentDecision
Don't Ship SeparatelyShipShip
Don't Ship SeparatelyShip
Don't Ship SeparatelyShip
Don't Ship SeparatelyDon't Ship SeparatelyDon't Ship Separately
ShipShipShip
Don't Ship SeparatelyShip
Don't Ship SeparatelyDon't Ship Separately
ShipDon't Ship Separately
ShipDon't Ship Separately
1. Same supplier
2. Same CoO 3. Same Date of Ship.
(1-7 days option)
Develop the basic consolidation methodology2-2
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III. Analyze > 3. Compare Net-benefit
Cost Reduction by Consolidation3
1 day
2 day
3 day
4 day
5 day
6 day
7 day
-
50,000
100,000
150,000
200,000
250,000
300,000 Customer Brokerage Fee
1 2 3 4 5 6 70
50000
100000
150000
200000
250000
300000
Maintenance Processing Fee
1 2 3 4 5 6 7 -
50,000
100,000
150,000
200,000
250,000
300,000 Total Saving
1)
2)
It is possible to delay the shipments by no more than four days without losing net benefit under the assumption that - delayed shipments imply the holding cost of vendor capital and reduce the net benefit of strategy
1) : $ per shipment2) : shipments delay options* : 1 implies shipment on the same day and 2 implies delayed by one day and so on.
*
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Agenda
I InitiateII RecommendationIII AnalyzeIV EnvisionV DesignVI Appendix
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IV. EnvisionWe envision the detailed consolidation model based on previous analysis. We reflect possible and critical constraints into the basic model
Initiate Analyze Envision DesignInitiate Analyze EnvisionInitiate Analyze
Reflect the Adjusted Fee of Carriers2
Reflect the Cost of Capital Investment1
…
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IV. Envision > 1. Cost of Capital Investment We need to take into account the inventory holding cost to the model because of in-creased inventory at carrier’s place
Delayed days Same day 1 day 2 days 3 days 4 days 5 days 6 days
Total invoice spend ($)
56,267,348
56,267,348
56,267,348
56,267,348
56,267,348
56,267,348
56,267,348
Period (Days) 180 180 180 180 180 180 180 Total invoice
spend/day
312,596
312,596
312,596
312,596
312,596
312,596
312,596 Holding cost ($) -
46,889
93,779
140,668
187,558
234,447
281,337 # of shipments in
period 3,054
3,054
3,054
3,054
3,054
3,054
3,054
Holding cost/Shipment - 15 31 46 61 77 92
Savings ($) over period
101,504
123,463
138,240
149,677
153,121
153,129
154,008
Savings ($)/day 564 686 768 832 851 851 856
Savings ($)/shipment 33 40 45 49 50 50 50
`
Net Savings = (Reduced CBF + Reduced MPF) – Inventory Holding Cost (i=15%)
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IV. Envision > 1. Cost of Capital Investment Sensitivity Analysis By Changing the value of interest rate, we get different net-savings shown as below, the conflict between the delay shipment strategy and cost of capital holding, would yield an upper limit on the interaction.
Case 1. Set i=15%
Even if 7 days consolidation provides the largest saving, due to the holding cost, it is not the optimal period of consolidation
Case 3. i=20%Case 1. Set i=15% Case 3. i=20%Case 1. Set i=15% Case 2. i=10%
: Savings/Shipme
nt
: Holding cost/Shipment : Net Savings/Shipment
1)
2)
2)
1) : $ per shipment2) : shipments delay options* : 1 implies shipment on the same day and 2 implies delayed by one day and so on.
*
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Agenda
I InitiateII RecommendationIII AnalyzeIV EnvisionV DesignVI Appendix
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V. DesignWe locate the consolidation points in some country
Initiate Analyze Envision DesignInitiate Analyze EnvisionInitiate Analyze
Example: Carrier Consolidation in Europe2
Location of Consolidation Points1
Future scope for Consolidation of shipment 3
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V. Design > 1. Location of Consolidation PointsIn addition to the principles of the basic consolidation model, we firstly concentrate on establishing consolidation point to the country where the shipments occurs more often
Current shipper scenario
Canada32%
Eu-rope23%
etc.45%
no. of shipments
Canada
20%
Eu-rope42%
etc.38%
Invoice value
Top freight sources 55% of shipments62% of invoice value are from Canada Europe
Option 1. Consolidate Carriers
Focused on reduction of freight cost by increasing share of business to top carriers
Option 2. Find possible consolidation points for Cross dock
Focused on freight cost, MPF, and CBF
Future scope
1. # of Shipments
2. Invoice Value
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V. Design > 2. Example: Carrier Consolidation in EuropeIn addition to the principles of the basic consolidation model, we firstly concentrate on establishing consolidation point to the country where the shipments occurs more often
Top 4 shipper countries in Europe
GB IE FR DE
22
12
4.4 3.3
invoice(%)
GB IE FR DE
6
11
2.6 1.8
shipment(%)
Top 2 carriers chosen for consolidation based on # of shipments Total invoice amount Total duty/fees
Top 2 carriers chosen for consolidation Federal Express Lufthansa
The net increase in business for these carriers 20% of the current size of business with Hamilton Sundstrand
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V. Design > 3.Futurescope for Consolidation of shipments
Sunday Monday Tuesday Wednesday Thursday Friday Saturday
87
219
343
545
461
297
436
136 145
306 327
604
393
477
97
293248
278
450506 516
121176
453
211
387359
681
154
259
328
407
328 331
581
128
341
413
280
526
289
411
97
242
536
395439
399
280
1-DAY 2-DAY 3-DAY 4-DAY 5-DAY 6-DAY 7-DAY
From the current consolidation strategy to delay shipments, the distribution of shipments over the week is still spread over all the seven days of the week. So there is still opportunity to improve the savings by consolidating the shipments days within the week. (i.e. ship only Monday or Tuesday or Monday & Tuesday)The upper limit on the interaction is still four days as per our earlier analysis
# of Ship-ments
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Thank you
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Agenda
I InitiateII RecommendationIII AnalyzeIV EnvisionV DesignVI Appendix
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Appendix.1. Macro codes
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Appendix.2. Excel works
1 DAY 4-DAYRow Labels Sum of Invoice value Row Labels Sum of Invoice value1 1932504.13 1 3406935.672 7289085.88 2 7542407.393 10303304.63 3 20457990.874 23714597.35 4 7322334.415 19498828.74 5 11515823.036 11064280.93 6 11387655.937 20370059.94 7 32539514.3(blank) (blank)Grand Total 94172661.6 Grand Total 94172661.62 DAY 5-DAYRow Labels Sum of Invoice value Row Labels Sum of Invoice value1 5416171.92 1 5508167.622 5278973.19 2 12229606.323 8725797.05 3 10883684.074 10307653.92 4 20469974.625 26410491.77 5 9325334.086 16561329.33 6 106563857 21472244.42 7 25099509.89(blank) (blank)Grand Total 94172661.6 Grand Total 94172661.63-DAY 6-DAYRow Labels Sum of Invoice value Row Labels Sum of Invoice value1 2972062.58 1 2848829.32 15104461.53 2 16843027.053 6339727.27 3 17812951.064 9999776.48 4 10254050.895 16436892.7 5 23508235.336 20576098.34 6 8896763.817 22743642.7 7 14008804.16(blank) (blank)Grand Total 94172661.6 Grand Total 94172661.6
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Appendix.2. Excel works
Ship-per coun-try
MEX MEX MEX MEX MEX MEX MEX MEX MEX MEX MEX MEX MEX MEX MEX
Ship-per city
SALTILLO
SANTA CATARINA
APO-DACA
APO-DACA
AR-VADA
CI-DAD 635-2 ZONA IND EL PO-TOSI
ES-COBEDO
FRACC IND B JUAREZ QUERETARO
MEX-ICO
MONTER-REY
QUERETARO
SAN LUIS PO-TOSI
SAN LUIS PO-TOSI
WINDSOR LOCKS
SAN SAL-VADOR
Lati-tude 25.36 25.683
3325.766
6725.766
67 39.88 23 18.91667 23 23 25.666
6720.625
56 22.15 22.15 41.92917 13.7
longi-tude
-100.98
-100.46
7-100.2 -100.2 -
105.11 -102-
97.1167
-102 -102-
100.317
-100.37
2
-100.98
3
-100.98
3
-72.627
8
-89.216
7
Shipper name No of shipments
In-voice value
Shipper country Shipper city Latitude Direc-
tionlongi-tude
PARKWAY PRODUCTS DE ME-XICO S DE RL 5 5138.
53MEX SALTILLO 25.36N -100.98 0 62.816
590.368
6690.368
661659.6
91282.07
69819.38
98282.07
69282.07
6974.792
29530.10
96356.93
59356.93
593182.1
711786.8
61FUNDICION AGUILAS SA DE CV 1 920.6
1MEX SANTA CATARINA 25.683333N
-100.46
762.816
5 0 28.27465
28.27465
1636.521
336.3782
827.4664
336.3782
336.3782
15.14623
562.4825
396.3814
396.3814
3119.894
1776.282
EZI METALES SA DE CV 87 359081MEX APODACA 25.76666
7N -100.2 90.36866
28.27465 0 0 1634.2
76357.58
03824.94
96357.58
03357.58
0316.132
22571.93
53409.95
26409.95
263093.9
231764.8
12PROCESOS TERMICOS Y ES-PECIALES 28 20279
.9MEX APODACA 25.766667N -100.2 90.368
6628.274
65 0 0 1634.276
357.5803
824.9496
357.5803
357.5803
16.13222
571.9353
409.9526
409.9526
3093.923
1764.812
SUNDYNE CORP 2 1633.12MEX ARVADA 39.88N -
105.111659.6
911636.5
211634.2
761634.2
76 0 1899.664
2453.546
1899.664
1899.664
1642.045
2187.919
2009.679
2009.679
2722.983
3298.878
TIGHITCO LATINOAMERICA SA DE CV 2 19275MEX CIDAD 635-2 ZONA IND
EL POTOSI 23N -102 282.0769
336.3782
357.5803
357.5803
1899.664 0 680.52
06 0 0 342.0562
312.9715
140.8167
140.8167
3438.133
1698.103
TECNOLOGIA PROCESOS Y MAQUINAR 1 330.7
2MEX ESCOBEDO 18.916667N
-97.116
7819.38
98827.46
64824.94
96824.94
962453.5
46680.52
06 0 680.5206
680.5206
819.4812
390.029
539.732
539.732
3447.779
1023.025
TURBORREACTORES SA DE CV 87 22540
9MEX FRACC IND B JUAREZ QUERETARO 23N -102 282.07
69336.37
82357.58
03357.58
031899.6
64 0 680.5206 0 0 342.05
62312.97
15140.81
67140.81
673438.1
331698.1
03TIGHITCO LATINOAMERICA SA DE CV 1 1089.
76MEX MEXICO 23N -102 282.0769
336.3782
357.5803
357.5803
1899.664 0 680.52
06 0 0 342.0562
312.9715
140.8167
140.8167
3438.133
1698.103
METALIZADOS Y MAQUINA-DOS DE MX 2 1043.
12MEX MONTERREY 25.666667N
-100.31
774.792
2915.146
2316.132
2216.132
221642.0
45342.05
62819.48
12342.05
62342.05
62 0 560.5745
396.8616
396.8616
3110.053
1764.616
TURBORREACTORES SA DE CV 6 14747
.9MEX QUERETARO 20.62555555N
-100.37
2530.10
96562.48
25571.93
53571.93
532187.9
19312.97
15390.02
9312.97
15312.97
15560.57
45 0 180.9435
180.9435
3515.06
1412.474
HAMILTON SUNDSTRAND (MX) 1 479.4
3MEX SAN LUIS POTOSI 22.15N-
100.983
356.9359
396.3814
409.9526
409.9526
2009.679
140.8167
539.732
140.8167
140.8167
396.8616
180.9435 0 0 3432.6
61558.3
21
TIGHITCO LATINOAMERICA SA DE CV 12 22125
.5MEX SAN LUIS POTOSI 22.15N-
100.983
356.9359
396.3814
409.9526
409.9526
2009.679
140.8167
539.732
140.8167
140.8167
396.8616
180.9435 0 0 3432.6
61558.3
21
HAMILTON SUNDSTRAND DOCK J BLD (MX) 1 578.1
4MEX WINDSOR LOCKS 41.9291667N
-72.627
83182.1
713119.8
943093.9
233093.9
232722.9
833438.1
333447.7
793438.1
333438.1
333110.0
533515.0
63432.6
63432.6
6 0 3522.853
OXIGENOS Y GASES DE 1 449.29MEX SAN SALVADOR 13.7N
-89.216
71786.8
611776.2
821764.8
121764.8
123298.8
781698.1
031023.0
251698.1
031698.1
031764.6
161412.4
741558.3
211558.3
213522.8
53 0