trb shrp2 symposium innovations in freight...
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TRB – SHRP2 SYMPOSIUM Innovations in Freight Demand Modeling and Data Improvement
October 21-22, 2013
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Hyster-Yale Snapshot
Hyster-Yale Materials Handling, Inc. (NYSE:HY)
NACCO Materials Handling Group, Inc. is an operating unit of
HY
Leading global designer, manufacturer and marketer of lift
trucks and provider of aftermarket parts and support
Build to order OEM
Headquartered in Cleveland, Ohio
Over 5,300 employees in 13 countries
FY 2012 Revenue – $2.5 billion
FY 2012 Net Income - $98.0 million
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Hyster-Yale Overview
Leading global lift truck brands in terms of units sold
– #3 globally in 2011 (2012 data not yet available)
Large installed base that drives parts sales
– Over 798,000 units worldwide
– Sales of more than 76,900 units in 2012
– Sales of more than 3,800 units at SN JV in Japan in 2012
Diverse customer and application base
Global independent dealer network
Comprehensive, updated global product line
Globally integrated operations with economies of scale
Experienced management team
Key Highlights Global Footprint
Mission Statement: Be a leading globally integrated designer, manufacturer and marketer of a complete range of high quality, application-tailored lift trucks, offering the lowest cost of ownership, outstanding parts and service support and the best overall value.
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Class Capacity Range Description / Illustrative Application
Class I 1 ton – 5.5 tons
Electric counterbalanced trucks used in warehousing and manufacturing operations where noise or fuel emissions are undesirable
A distribution center customer uses a Class I truck to move pallets from one trailer to another
Class II 1.5 tons – 6 tons
Electric narrow aisle trucks used indoors to handle high-density storage of materials in narrow-aisled buildings
Retail and warehouse customers rely on Class II trucks to pick orders off their shelves
Class III 1.5 tons – 8 tons
Electric hand trucks used indoors and outdoors for applications requiring the user to select and transport materials
Retail customers use Class III trucks to move pallets of goods to their store aisles
Class IV 1 ton – 7 tons
Internal combustion engine counterbalanced trucks with cushion tires used indoors in warehousing and manufacturing operations and outdoors on smooth surfaces. Utility, standard and premium models for different customer applications.
A customer relies on Class IV trucks to move heavy parts on a pallet from the machining area in a factory to assembly
Class V 1 ton – 8 tons
Internal combustion engine counterbalanced trucks with pneumatic tires used indoors and outdoors in warehousing and manufacturing operations. Utility, standard and premium models to address different customer applications.
A warehouse or manufacturer relies on Class V trucks to move coils of steel from the mill to a storage area
Class V Big Trucks
8 ton – 52 tons
Internal combustion engine counterbalanced trucks with pneumatic tires used indoors and outdoors in ports and heavy manufacturing operations
A port relies on Class V Big Trucks to move containers from the port to a rail area
Comprehensive Product Line
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Challenges to Today’s Manufacturing Logistics Network
• Globalization o Suppliers and Customers o Carriers and Service Providers o Planning for an Extended
Supply Chain o Security
• Regulation o Driver Hours of Service
Reductions o Importer Security Filing (ISF,
aka “10 + 2”) o Hazardous Material
• Inventory Reduction o Vendor Managed Inventory o Forward Stocking o Replace Inventory with
Information!
• Customer Service o Increase in Competitive
Pressures o Right Product/Right Time/Right
Place/ Right Condition/Right Price o Customers Demand More
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Inbound Transportation Modeling – Current State
• Utilize historical data sets o Freight bill payment files o Carrier shipment level detail reports
• Identify trends within a rolling 6-month period of time o Origin & destination combinations o Shipment frequency o Weights, volumes, piece counts
• Work with carriers & suppliers to validate feasibility o Does the supplier have room to hold material? o Can the carrier meet the required service expectation?
• Primary goal is to move from small, expensive shipments that are unplanned to cost effective shipments that are scheduled for delivery.
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Inbound Transportation Modeling – Current State Benefits & Limitations
• Benefits: o Regular shipping schedule for suppliers. Same day of the week, same
carrier, in some cases… even the same driver. o Stability within planning system. Parts will arrive same time every week. o Leveling of workload at manufacturing receiving docks. We can adjust
delivery plans to fit slower activity times. o Transportation cost reduction.
• Limitations: o Slow to recognize changes. Working with historical data requires 3
months worth of transactions in order to determine trend vs. anomaly. o Decisions are not shipment specific, instead they are based on the overall
activity level during a period of time. o No consideration of future changes to SC network. In a sense, it is
looking in the review mirror to see where you are going.
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Inbound Transportation Modeling – Current State Example
Fm City Fm St Fm Zip To Loc ID To Name To City To St To Zip Carrier Mode Shp Wgt PCS Vol Shp Frt$
GREENVILLENC '27834 'NMHG-11699CARRARO NORTH AMERICACALHOUN GA '30701 RBTW TL 20898 21 0 501.95
GREENVILLENC '27834 'NMHG-00038BLACK EQUIPMENT COMPANY, INC.EVANSVILLEIN '47715 MCET TL 1510 1 0 261.17
BEREA KY '40403 'NMHG-103151GM POWERTRAIN GROUPROMULUS MI '48174 NDIN TL 44500 20 0 792.05
BEREA KY '40403 'NMHG-103995CASCADE CORPORATIONFINDLAY OH '45840 NDIN DTL 22500 10 0 576.36
FINDLAY OH '45840 'NMHG-10ANMHG-BEREA PLANTBEREA KY '40403 NDIN DTL 22000 10 0 563.55
FINDLAY OH '45840 'NMHG-72ANACCO-PLANTGREENVILLENC '27834 BLAC TL 44500 20 0 1440.24
FORT PAYNEAL '35967 'NMHG-10ANMHG-BEREA PLANTBEREA KY '40403 RCSC TL 44500 20 0 693.84
BEREA KY '40403 'NMHG-CARGOQCARGOQUIN, INCLAREDO TX '78041 RCSC TL 44500 20 0 2727.45
CHERRYVILLENC '28021 'NMHG-72ANACCO-PLANTGREENVILLENC '27834 MCET TL 44500 20 0 789.57
CHERRYVILLENC '28021 'NMHG-72ANACCO-PLANTGREENVILLENC '27834 BTTE TL 44500 20 0 738.67
DAVENPORTIA '52802 'NMHG-10NACCO MATERIALS HANDLINGRICHMONDKY '40475 MCET STL 44500 20 0 1563.77
MIRROR LAKENH '03853 'NMHG-72ANACCO-PLANTGREENVILLENC '27834 GEIF TL 44500 20 0 1306.74
LEWISBURGTN '37091 'NMHG-8 NACCO MATERIALS HANDLINGSULLIGENTAL '35586 NEWM STL 44500 20 0 831.6
GREENVILLENC '27834 'NMHG-NACCFAPNACCO/FAPCO MATLS HANDLING GROUPBUCHANANMI '49107 GEIF TL 44500 20 0 1826.66
HOMEWOODIL '60430 'NMHG-72ANACCO-PLANTGREENVILLENC '27834 GEIF TL 44500 20 0 2181.24
RICHMONDKY '40475 'SHIPTO OOCL NORFOLK VA '23501 EXPT PPAY 7720 1 0 0
RICHMONDKY '40475 'SHIPTO OOCL NORFOLK VA '23501 EXPT PPAY 7715 1 0 0
Historical Data Analysis Opportunity Identification Shipment #1 = 5,000 lbs., 3 pallets, Monday
Shipment #2 = 7,000 lbs., 2 pallets, Wednesday
Shipment #3 = 4,000 lbs., 4 pallets, Thursday
Supplier & Carrier Collaboration 1) Determine if carrier has capacity.
2) Confirm supplier has space to hold freight.
3) Select the optimal loading day and time.
4) Set service expectations.
Shipment Consolidation 1) Single shipment of 16,000 lbs.
2) Picked up from supplier every Wednesday.
3) Delivered to manufacturer every Thursday.
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Inbound Transportation Modeling – Future State
• Utilize open PO file o Work with future requirements vs. historical performance. o Planning resources have ability to see the shipment detail prior to carrier
pick-up.
• Identify optimization opportunities based on real-time data feeds
• Primary goal is “optimization” o Shipment Method = Need o No longer saving transportation cost at the expense of inventory. o No longer reducing inventory at the expense of transportation cost. o Right parts delivered at the right time at the right cost.
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Inbound Transportation Modeling – Future State Benefits & Limitations
• Benefits: o Improved visibility throughout supply chain o Stability within planning system o Leveling of workload at manufacturing receiving docks o Appropriate levels of inventory o Transportation cost reduction o Avoidance of premium modes of transport (air, team drivers)
• Limitations: o IT investment o Communication channels must be efficient o Requires implementation of software solutions
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Outbound Transportation Modeling
• Multi-Stop Truckload
• Must Meet Customer Need
• Efficient Route Design o Minimize stops in order to reduce chance for delays. o Avoid congested metropolitan areas for first delivery. o Group deliveries by region. o Limit “out-of-route” miles. Design should be as close to Point A to Point B
as possible (even if there are Points C & D)
• Operationally Practical o Total load weight should range between 38,000 and 44,000 lbs. o Majority of load weight should deliver to final destination. o Proper product mix in the trailer.
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Measuring Outbound Load Efficiency
• “Perfect” Load Score
(In-Route Mileage %) X (Total Weight %) X (Final Stop % of Total Weight) = Load Efficiency
X X =
Actual Miles: 2,609
Direct Miles: 2,598
Out of Route: 11 (.4%)
In-Route Mileage %
99.6%
Total Weight: 40,238 lbs.
Avail. Weight: 44,000 lbs.
Under Utilization: 3,762 (8.5%)
Total Weight %
91.5%
Final Stop Weight: 38,958 lbs.
Total Weight: 40,238 lbs.
Under Utilization: 1,280 (3.2%)
Final Stop Weight %
96.8%
88.2%
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Transportation Modeling – Key Considerations
• Is it cost effective? • Does it meet desired service requirement? • How do we mitigate risk? • Are there implementation costs? • Can it be managed? • How will it be measured? • Are there intangible benefits?
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Transportation Modeling – Assumptions
• Road & Highway Infrastructure o Support 500 miles per day o Minimize delays when operating outside of interstate system
• Port Facilities and Access o Quick vessel turnarounds o Containers off port within 24 – 48 hours o Effective rail interfaces
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Transportation Modeling – Future
• What can be done to mitigate the impact of regulatory limitations on drivers’ hours of service?
• How do we make the use of intermodal services a more viable option?
• How will larger container vessels calling US east coast ports impact current infrastructure?
• Is it possible to offset energy costs with more efficient transportation networks?
• Continued move away from Point A to Point B shipments.
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Transportation Modeling – Questions?
Thank You!
Andy Street, MS, CSCP
Order Fulfillment & Logistics Manager NACCO Materials Handling Group, Inc.
[email protected] (252) 412-3110