reading the tea leavescdn.modexshow.com/seminars/assets-2014/217.pdf · storage sizing right...
TRANSCRIPT
© 2014 MHI®
Copyright claimed as to audiovisual works of seminar sessions and
sound recordings of seminar sessions. All rights reserved.
Presented by:
Dean M. Starovasnik
Reading the Tea Leaves: How Big Data Modeling Can Prepare
Your Facility for Handling Omni-
Channel Fulfillment
Sponsored by:
P E A C H S T A T E
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
Overview
Data-based Design Process
Case Study
Agenda
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
Overview
3
Evolution of DC Design
Rules of Thumb
Mathematical Tools
Big Data Modeling
Selecting an Order Fulfillment Methodology (OFM)
Profiles should drive this critical decision
o Order profiles
o SKU profiles
o Activity (daily, hourly) profiles
Often more than one
Objective: minimize handling, maximize service level
“The Recipe”
Two questions: “How big?” & “How fast?”
Numbers of pallets, slots, facings, locations, doors, etc.
Throughput parameters and requirements.
First of all, some initial thoughts before we get too far into this.
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
“Big Data” Definition
4
Big Data in DC design
Full disclosure
Variety of sources
Future projections
Sources of data
Demand
o Order entry system
o ERP
o WMS
Product – Item Master (major sticking point)
o ERP/MRP
o WMS
Transportation
o TMS
o 3rd Party
Synchronization of data is critical
While definitions vary, Big Data is normally thought to include disparate, diverse data in the realm of terabytes and petabytes or trillions and quadrillions of bytes.
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
Facility Design Profiles
6
Planning &
Design Issue
Key Focus Primary Data
Source
Profiles
Order
Fulfillment
Methodologies
Effective strategies for
picking & packing
(e.g., zone pick & sort
opportunities?)
Order & Item
Master Files
• Per order distributions (lines, units, cartons, cube, etc.)
• Per carton distributions
• Order mix/completion distribution
• Handling unit profile (broken/full case, full pallet, mixed)
Storage Sizing Right storage media &
corresponding facings
for reserve slots
Location,
Inventory &
Item Master
• ABC inventory distribution (Pareto)
• Handling unit (pallets, cube, cases, etc.) inventory profile
Warehouse
Zone & Facing
Requirements
Right storage media &
corresponding facings
for primary slots
Order, Item
Master &
Location Files
• ABC activity (Pareto) profile
• Cube movement distribution
• Storage zone profiles (SKUs, volumes, etc. by special
requirements - drug, cooler, etc.)
Material
Handling
Throughput &
Capacity
Peak hourly volumes
to be processed
Order, Ship &
Item Master
Files
• Daily activity profile (orders, lines, full cases, split cartons,
total boxes)
• Hourly activity distribution (particularly with respect to
order drop & cutoff times)
Profiles of different data elements help to address the variety of questions that must be answered in the facility design effort.
The collection of these profiles represents a historical model of the operation.
The next step is to “grow” this model into the future across all parameters.
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
“Growing” Profiles
7
Volume Sales projections
o NOT from the VP sales (sandbagging)
o CEO/COO are the best bet
Mergers & Acquisitions
Demographic demand baseline
SKU Historical behavior
o New product initiatives
o Market requirements
o Obsolescence (or lack of it)
Mergers & Acquisitions (again) o Cannibalization
o Brand management
Order Mix Market behavior
Historical trends
The rear view mirror only helps you identify whose catching up on you.
The historical models now need to be projected into the future.
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
Profiling – Input to the OFM Decision
8
Order
Profiles
Handling Unit
Profiles
SKU
Profiles
ORDER
FULFILLMENT
METHODOLOGIES
Broken
Case
OFMs
Full
Case
OFMs
Primary Manual vs. Automated Considerations:
• Throughput requirements (hourly volumes)
• Labor requirements (amount, cost, availability)
• Service requirements (accuracy, service levels,
costs of non-conformance)
• Per ship method o Per order distributions
o Per carton distributions
• Order completion
• Single line percentage
• Per day & hour distributions
• Full Case %
• Broken Case %
• Full Pallet %
• Mixed Orders %
• Special handling o Lot control
o Hazmat
o Refr/Freezer
• ABC (Pareto) Distribution
• Full Case, Broken Case,
Full Pallet Volumes
• Cube movement
Once the future state has been developed, identifying the correct OFM’s for each portion of the operation is the first step in developing the facility design.
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
Case Study
Project Overview
Data Analysis Activity Profiles
SKU Profiles
Container Profiles
Requirements Definition
Facility Design
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
Project Overview
11
Growing through the recession (20%).
Recently purchased by a private equity firm
High profile, luxury product identity
Persistent demand from existing customers
New customers gained through DTC and home shopping
Was in two fulfillment facilities
Both space constrained
Retail & home shopping fulfilled in one facility
DTC fulfilled (from same SKU base) at HQ
Spec building selected prior to completion of design
Size and door count validated immediately
Sufficient for five years and beyond
Some expansion capability available
The design project we are reviewing is actually in the midst of an ownership transition at present. Therefore, the client identity will remain hidden.
Customer was moving very fast, had an aggressive growth
strategy and desired rapid evidence of return on investment.
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
Case Study
Project Overview
Data Analysis Activity Profiles
SKU Profiles
Container Profiles
Requirements Definition
Facility Design
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
Outbound Profiles – Daily Activity
13
The below statistics help to illustrate the activity levels of the combined business, Retail DSDC and DTC channels.
Parameter Orders/day Lines/day Units/day CubicFeet/day Weight/day SKUs/day
Average 934 3,875 23,748 502 14,931 328
95th Percentile 2,240 9,485 77,391 1,420 43,814 454
Max 3,882 14,611 135,662 2,802 87,689 473
Peak to Avg 2.40 2.45 3.26 2.83 2.93 1.39
Parameter Orders/day Lines/day Units/day CubicFeet/day Weight/day SKUs/day
Average 894 3,282 3,430 71 1,794 308
95th Percentile 2,227 8,197 8,922 190 5,024 417
Max 3,815 14,160 14,721 374 8,503 460
Peak to Avg 2.49 2.50 2.60 2.70 2.80 1.36
Parameter Orders/day Lines/day Units/day CubicFeet/day Weight/day SKUs/day
Average 87 765 10,278 226 6,765 103
95th Percentile 254 2,145 33,098 801 22,907 178
Max 482 3,214 91,685 1,459 50,182 218
Peak to Avg 2.93 2.80 3.22 3.54 3.39 1.72
Combined
Retail DSDC
DTC
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
Outbound Profiles – Order Statistics
14
The below statistics help to illustrate the nature of the orders across the combined business, Retail DSDC and DTC channels.
Combined
Retail DSDC
DTC
Parameter Lines/Order Units/Order Cubic/Order Weight/Order Units/Line
Average 4.7 52.8 1.0 30.3 8.6
95th Percentile 8.1 176.4 2.9 85.7 22.4
Max 37 2,251 34 1,043 172
Peak to Avg 1.73 3.34 2.85 2.83 2.60
Parameter Lines/Order Units/Order Cubic/Order Weight/Order Units/Line
Average 3.6 3.8 0.1 2.0 1.1
95th Percentile 4.4 4.6 0.1 3.0 1.1
Max 8 8 1 8 8
Peak to Avg 1.20 1.22 1.38 1.50 1.05
Parameter Lines/Order Units/Order Cubic/Order Weight/Order Units/Line
Average 11.1 277.8 6.5 200.9 24.9
95th Percentile 24.8 927.2 19.6 592.8 120.2
Max 56 7,372 304 9,288 413
Peak to Avg 2.23 3.34 3.01 2.95 4.82
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
Outbound Profiles - Throughput
15
The daily throughput profile reveals considerable seasonality, peaking in October & November.
0
20,000
40,000
60,000
80,000
100,000
120,000
140,000
Ap
r-0
9
May
-09
Jun
-09
Jul-
09
Au
g-0
9
Sep
-09
Oct
-09
No
v-0
9
De
c-0
9
Total (No QVC) Daily Outbound Units Shipped
Units 95th Percentile Average
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
Outbound Profiles - DTC
16
The daily throughput profile reveals considerable seasonality, peaking in November.
0
2,000
4,000
6,000
8,000
10,000
12,000
14,000
16,000
Ap
r-0
9
May
-09
Jun
-09
Jul-
09
Au
g-0
9
Sep
-09
Oct
-09
No
v-0
9
De
c-0
9
Internet Daily Outbound Units Shipped
Units Average Percentile
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
Outbound Profiles – Retail DSDC
17
The daily throughput profile reveals some seasonality, peaking in September & October.
0
10,000
20,000
30,000
40,000
50,000
60,000
70,000
80,000
90,000
100,000
Ap
r-0
9
May
-09
Jun
-09
Jul-
09
Au
g-0
9
Sep
-09
Oct
-09
No
v-0
9
De
c-0
9
Daily Retail (DSDC) Outbound Units Shipped
Units Average Percentile
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
Outbound Profiles – Lines Per Order
18
Lines per order profiles were developed for Retail DSDC and DTC orders.
21%
32%
19%18%
9%
1% 0%0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0%
5%
10%
15%
20%
25%
30%
35%
1 2-5 6-10 11-20 21-50 51-100 >100C
um
Pct
Pct
Retail - DSDC Lines per Order
Pct Orders Pct Lines Cumm Pct Orders
16%
69%
15%
0% 0% 0% 0%0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0%
10%
20%
30%
40%
50%
60%
70%
80%
1 2-5 6-10 11-20 21-50 51-100 >100
Cu
m P
ct
Pct
Internet Lines per Order
Pct Orders Pct Lines Cumm Pct Orders
Average 8.8 Average 3.7
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
0%5%
12%18%
27%
17%20%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
1 2-5 6-10 11-20 21-50 51-100 >100C
um
Pct
Pct
Retail DSDC Units per Order
Pct Orders Pct Units Cumm Pct Orders
14%
68%
16%
1% 0% 0% 0%0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0%
10%
20%
30%
40%
50%
60%
70%
80%
1 2-5 6-10 11-20 21-50 51-100 >100
Cu
m P
ct
Pct
Internet Units per Order
Pct Orders Pct Units Cumm Pct Orders
Outbound Profiles – Units Per Order
19
Unit per order profiles were developed for Retail DSDC and DTC orders.
Average 118.6 Average 3.9
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
5%2%
9%
24%22%
35%
3%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0%
5%
10%
15%
20%
25%
30%
35%
40%
45%
0-0.0025 0.0025-0.005 0.005-0.01 0.01-0.03 0.03-0.05 0.05-0.1 >0.1
Cu
m P
ct
Pct
Internet Cubic Feet per Order
Pct Orders Pct Lines Cumm Pct Orders
23%
14%
20%
12%
24%
5%3%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0%
5%
10%
15%
20%
25%
30%
35%
40%
45%
0-0.25 0.25-0.5 0.5-1 1-1.5 1.5-5 5-10 >10C
um
Pct
Pct
Retail DSDC Cubic Feet per Order
Pct Orders Pct Lines Cumm Pct Orders
Outbound Profiles – Cube Per Order
20
Cube per order profiles were developed for Retail DSDC and DTC orders.
Average 2.6 Average 0.0
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
43%
19% 18%
13%
4%2% 1%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0%
5%
10%
15%
20%
25%
30%
35%
40%
45%
50%
1 2 3-4 5-10 11-20 21-50 >50C
um
Pct
Pct
Retail DSDC Cartons per Order
Pct Orders Pct Cartons Cumm Pct Orders
100%
0% 0% 0% 0% 0% 0%100%
100%
100%
100%
100%
100%
100%
0%
20%
40%
60%
80%
100%
120%
0-1 2 3 4 5 6-15 >15
Cu
m P
ct
Pct
Internet Cartons per Order
Pct Orders Pct Cartons Cumm Pct Orders
Outbound Profiles – Cartons Per Order
21
Cartons per order profiles were developed for Retail DSDC and DTC orders.
Average 1.0 Average 3.4
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
Case Study
Project Overview
Data Analysis Activity Profiles
SKU Profiles
Container Profiles
Requirements Definition
Facility Design
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
Pareto Profile - Lines
23
A Pareto profile helps illustrate the concentration (or lack thereof) of activity within a particular range of products. The below shows the variation in line activity across the SKU base for Retail, DTC and Combined orders.
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0% 10% 20% 30% 40% 50% 60% 70% 80% 90%
Retail Pareto by Lines
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0% 10% 20% 30% 40% 50% 60% 70% 80% 90%
Internet Pareto by Lines
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0% 10% 20% 30% 40% 50% 60% 70% 80% 91%
Combined Pareto by Lines
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
Pareto Profile - Units
24
The below shows the variation in unit activity across the SKU base for Retail, DTC and Combined orders.
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0% 10% 20% 30% 40% 50% 60% 70% 80% 91%
Combined Pareto by Units
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0% 10% 20% 30% 40% 50% 60% 70% 80% 90%
Retail Pareto by Units
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0% 10% 20% 30% 40% 50% 60% 70% 80% 90%
Internet Pareto by Units
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
Total Active SKUs by Month
25
As the below graph shows, the total number of all SKUs active in a month grows into the peak period to just over 800 SKUs. This compares to the baseline of ~1,370 total SKUs with any activity in the Apr – Dec ‘09 window that was analyzed.
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
Case Study
Project Overview
Data Analysis Activity Profiles
SKU Profiles
Container Profiles
Requirements Definition
Facility Design
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
Outbound Profiles – Full Case vs. Broken Case
27
To determine how orders “are” fulfilled, full case and broken case volumes were calculated for both Retail DSDC and DTC orders, first in lines.
-
100,000
200,000
300,000
400,000
500,000
600,000
700,000
800,000
All Channels Retail Internet Ulta Sephora
Lines
Both
Broken Case Only
Full Case Only
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
All Channels Retail Internet Ulta Sephora
All Retail Internet Ulta Sephora
Total 771,105 150,695 620,410 2,533 5,915
Full Case Only 52,824 42,197 10,627 956 1,279
Broken Case Only 682,098 100,143 581,955 937 1,346
Both 8,065 7,949 116 615 3,187
All Retail Internet Ulta Sephora
Full Case Only 6.85% 28.0% 1.71% 37.7% 21.6%
Broken Case Only 88.46% 66.5% 93.80% 37.0% 22.8%
Both 1.05% 5.3% 0.02% 24.3% 53.9%
Lines - Quantity
Lines - %
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
Outbound Profiles – Full Case vs. Broken Case
28
To determine how orders “are” fulfilled, full case and broken case volumes were calculated for both Retail DSDC and DTC orders, next in units.
All Retail Internet Ulta Sephora
Total 4,725,811 4,077,473 648,338 256,854 1,908,940
Full Case Only 3,263,052 3,249,327 11,504 221,555 1,778,472
Broken Case Only 1,456,572 828,025 628,547 35,298 130,465
All Retail Internet Ulta Sephora
Full Case Only 69.0% 79.7% 2.1% 86.3% 93.2%
Broken Case Only 30.8% 20.3% 97.9% 13.7% 6.8%
Units - Quantity
Units - %-
500,000
1,000,000
1,500,000
2,000,000
2,500,000
3,000,000
3,500,000
4,000,000
4,500,000
5,000,000
All Retail Internet Ulta Sephora
Units
Broken Case Only
Full Case Only
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
All Retail Internet Ulta Sephora
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
Case Study
Project Overview
Data Analysis Activity Profiles
SKU Profiles
Container Profiles
Requirements Definition
Facility Design
Table of Contents
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
Growth Projections
30
The different fulfillment channels contribute varying amounts to the overall corporate growth of the client.
Year 2009 2010 2011 2012 2013 2014 2015
Total Revenue $150.0 $188.0 $238.0 $300.0 $330.0 $363.0 $399.3
Internet Volume 10.9% $16.4 $24.9 $40.4 $60.0 $63.6 $67.4 $71.5
Retail Volume 71.3% $107.0 $91.1 $121.1 $159.0 $183.0 $209.7 $239.3
QVC Volume 17.7% $67.5 $72.0 $76.5 $81.0 $83.4 $85.9 $88.5
Internet Vol % 10.9% 14.0% 17.0% 20.0% 19.3% 18.6% 17.9%
Retail Vol % 71.3% 48.4% 50.9% 53.0% 55.4% 57.8% 59.9%
QVC Vol % 17.7% 38.3% 32.1% 27.0% 25.3% 23.7% 22.2%
Growth 25% 27% 26% 10% 10% 10%
QVC Growth Rate 3% 3% 3% 3% 3% 3% 3%
Multiplier 1.00 1.25 1.59 2.00 2.20 2.42 2.66
Turns 4.00 4.17 4.33 4.50 4.67 4.83 5.00
Turns Change Mult 0.96 0.96 0.96 0.96 0.97 0.97
Year 0 Year 1 Year 2 Year 3 Year 4 Year 5 Year 6
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
Storage Requirements
31
Storage requirements were calculated based on increases in shipping volumes for all three channels. Baseline storage for Year 0 was calculated from inventory data for retail and DTC volumes as well as historical location requirements for the Primary Location storage.
Note that the driving factor is kitting storage. The growth associated
with this area does not overcome the improvement in turns past Year 3.
Category 2009 2010 2011 2012 2013 2014 2015 Max Util
QVC/Internet 1,697.7 1,762.0 2,236.5 2,169.5 1,796.0 1,793.5 1,790.5 2,236.5 85%
KA Components 7,000.0 7,168.0 7,323.1 7,466.7 7,416.0 7,375.1 7,343.1 7,466.7 Capacity
Total 8,697.7 8,930.0 9,559.6 9,636.2 9,212.0 9,168.6 9,133.6 9,636.2 11,337
Pallet Inventory
Year 0 Year 1 Year 2 Year 3 Year 4 Year 5 Year 6
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
Pick Module Sizing
32
Each SKU was assessed for its broken case volume flow, both DTC and Retail. These volumes were then assigned to pick media. Replenishment was assumed to be every four days on average for a slot classification.
A “slice” is one bay wide, includes both sides and all levels of the module.
The number of slices determines the overall length of the module.
MediaSKUs 2010 2011 2012 2013 2014 2015
Faces/
SKU
Face/
Bay2012 2015
PF 57 63 69 76 84 92 101 1 2 40 54
CF - 3 27 30 33 36 40 44 48 3 40
CF - 2 69 76 84 92 101 111 122 2 40
CF - 1 113 124 136 150 165 182 200 1 40 12 16
Shelf - 3 69 76 84 92 101 111 122 3 120
Shelf - 2 125 138 152 167 184 202 222 2 120
Shelf - 1 907 998 1,098 1,208 1,329 1,462 1,608 1 120 16 22
Total SKUs 1367 1,505 1,656 1,821 2,004 2,204 2,423 Total Bays 68 92
SKU Growth 10% 10% 10% 10% 10% 10% Bays/Slice 4 6
Slices 17 15
Bays
Year 1 Year 2 Year 3 Year 4 Year 5 Year 6
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
Case Study
Project Overview
Data Analysis Activity Profiles
SKU Profiles
Container Profiles
Requirements Definition
Facility Design
Table of Contents
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
Facility Overview
34
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
Material Flow
35
Key
Inbound
Internal
Outbound
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
Reserve Storage
36
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
OFM Rationale & Criteria
Multi-channel order fulfillment in common areas provides numerous benefits: Improved utilization of labor throughout year
Increased opportunity to use shipping sortation automation
Common shipping area increases flexibility due to variations in channel seasonality
Handling full case pulls separately from piece picks allows for proper slotting of the
SKU by cubic velocity in that UOM while reducing the walk time for piece picks.
Performing all piece picks in a common module consolidates repack operations in
one location for enhanced process control and efficiency.
Consolidation normally creates considerable opportunity for error while increasing
non-value added handling. Using a shipping sorter to assist with palletization of
LTL and fluid load of parcel carriers will reduce non-value added handling and
improve quality.
Repack replenishment can also be supported by “picking” the required
replenishment cases, and then delivering to the repack module, either via conveyor
or, after palletizing by SKU, by vehicle.
The expected benefit of the zone pick & consolidate order fulfillment methodology is a reduction in non-value added labor and an improvement in quality & cycle time.
37
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
ZPP – Rationale
Cartons requiring units from multiple zones must be manually moved from zone to
zone increasing walk time by pickers.
Pickers remaining in their zones while conveyor moves the cartons from zone to
zone will eliminate the non-value walk time.
By separating full case volumes from broken case, the pick faces in the ZPP can
be reduced to minimize pick travel paths.
Appropriate configuration of powered and gravity conveyors can assist with the
passing required to complete cartons.
A pick and pass OFM for less than case picking provides a reduction in of non-value added labor, specifically walking.
38
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
Broken Case Pick Module
39
A pick module comprised of pallet flow, carton flow and static shelving pick faces provides the flexibility and efficient order fulfillment for broken case demand across both Retail and DTC channels.
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
Full Case Pick to Label Rationale
Retail orders require a large portion of their volume in full case quantities (80%).
Creating a full case pick zone using a
pick to label approach will eliminate
the non-value added handling of
repacking all case quantities into
repack containers.
Pick to label addresses the issue with
small cases while retaining efficient
picking. Cases 3” tall or less will be
handled as piece picks.
Repack replenishment can also be supported by “picking” the required replenishment
cases, palletizing by SKU and then delivering to the repack module.
The expected benefit of a pick to label full case area is an elimination of non-value added repack activity while improving quality through automated verification of all cases at the shipping sorter.
-
500,000
1,000,000
1,500,000
2,000,000
2,500,000
3,000,000
3,500,000
4,000,000
4,500,000
5,000,000
All Retail Internet Ulta Sephora
Units
Broken Case Only
Full Case Only
40
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
Full Case Pick Lines
41
The below two lanes with shelving in 3 bays at the downstream end support over 99.2% of the full case units, 73% of those in the pallet flow bays.
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
SKUs 285 96.6% of case volume
Pallet Flow Bays 143 2 SKUs/bay
Conveyor Length 590 8.25 Bay width
Connecting Conv. 50
Total Conv. 640
Pallet Flow $100,600
Conveyor $304,200
MHE Total $404,800
Access to Sorter
Pick To Belt – MHE Capital
42
The Pick to Belt concept is quite simple and economical. The below budgetary estimate illustrates the expected capital needed to implement this capability.
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
Shipping
43
The shipping sorter supports a peak throughput of less than 40 cpm. Technology of this type can manage approximately twice that, if necessary.
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
By developing an accurate MHE budget, the client was able to determine the overall return on investment of this consolidation step.
Detailed Budget
44
Category Investment Descriptions
Reserve Rack $417,100 6,500 new pallet positions, 6,000 used relocated
Pick Module $375,900 18 slices, 2/3 pallet flow, 1/6 carton flow, 1/6 shelving
Pack Stations $7,000 4 pack stations, 1 singles pack station, 1 QA capable station
Full Case Conveyor $110,300 2 pick aisles plus merges, including 3 shelf bays & flow lanes
Pick Module Conveyor $197,500 two levels power, gravity outriggers, gates
Spiral $48,000 second to first level, powered
Sorter Conveyor $232,500 recirc, accumulation, merge, pack station conveyor, lanes
Sorter $215,000 11 diverts (6 reused), 9 LTL, 1 parcel, 1 NR/Reject
WCS $140,000 WMS interface, sorter, accumulation control
Total $1,743,300
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
The modifications to the order fulfillment method we have recommended will affect only the outbound personnel. Below lays out our conservative estimate for that staff.
Outbound Staffing
45
Rates Daily Activity 2009 2010 2011 2012 Peak 2013 2014 2015 Max Peak P2A Units
Shipping (cpd) 2,126 2,664 3,373 4,251 11,643 4,912 5,404 5,658 5,658 15,496 2.74 cases
24 Palletization 1,052 1,318 1,669 2,103 5,760 2,430 2,674 2,799 2,799 7,667 2.74 cases
150 cph 1.0 1.5 1.5 2.0 4.0 2.5 2.5 2.5 2.5 5.0 Pltzr FTEs
20 Fluid Load 1,074 1,346 1,704 2,148 5,882 2,482 2,730 2,859 2,859 7,829 2.74 cases
180 cph 1.0 1.0 1.5 2.0 3.0 2.0 2.0 2.5 2.5 4.5 Loaders FTEs
60 Packing 1,074 1,346 1,704 2,148 5,882 2,482 2,730 2,859 2,859 7,829 2.74 cartons
60 cph 2.5 3.5 4.0 5.5 9.5 6.0 6.5 7.0 7.0 13.0 Packers FTEs
36 Broken Case Picking 2,634 3,301 4,179 5,268 12,447 5,795 6,374 7,012 7,012 16,567 2.36 lines
100 lph 4.0 5.0 6.0 7.5 12.0 8.5 9.5 10.5 10.5 16.0 Pickers FTEs
14 Full Case Picking 1,052 1,318 1,669 2,103 5,760 2,314 2,545 2,799 2,799 7,667 2.74 cases
250 cph 0.5 1.0 1.0 1.0 2.5 1.5 1.5 1.5 1.5 3.0 Pickers FTEs
36 Broken Case Replen 1,074 1,346 1,704 2,148 5,882 2,482 2,730 2,859 2,859 7,829 2.74 cases
100 cph 1.5 2.0 2.5 3.0 6.0 3.5 4.0 4.0 4.0 7.5 PJ FTEs
Total FTEs (avg) 11.0 14.0 17.0 21.0 35.0 24.0 26.0 28.0 28.0 49.0 Peak FTEs
Note: Peak values reflect operating for 1.5 shifts for peak.
© 2014 Peach State Integrated Technologies. Contents are confidential. All rights reserved.
For More Information:
Speaker email: [email protected]
Website: www.peachstate.com
Or visit MODEX 2014 Booth #4329
NOTE: This ending slide is OPTIONAL. Items that can be included are your
speaker’s email address/home page, the Exhibiting Member Company’s name,
home page and Booth Number.