Cómo afrontar los retos de los almacenes del futuro. Resultados del proyecto RAFUWARE Investigadores principales Tecnun: Dra. Claudia Chackelson Dr. Javier Santos Colaboración - ITA : David Ciprés Miriam García
Agenda Contextualización Proyecto RAFUWARE Resultados Tecnun Resultados ITA (casos prácticos) Conclusiones
Contextualización Aumento de la complejidad La complejidad de los almacenes ha aumentado en los últimos años Parte de este aumento de la complejidad se debe a estrategias que ha adoptado las empresas para aumentar la tasa de mercado diversificación e-commerce
Contextualización Aumento de la complejidad Preparar Más Pedidos Almacenar Más Referencias Servir Más Personalizado Añadir Más Valor Con Menos Plazo de entrega Con Menos Margen de error
Contextualización Motivos para (re)diseñar un almacén Un nuevo almacén Bajos niveles de servicio y/o altos costes Redefinición de las funciones Cambio en la Complejidad de los procesos
Contextualización Importancia del diseño El DISEÑO de almacenes es un problema complejo 1 el número de 2 alternativas posibles la fuerte interacción entre los factores involucrados Sin embargo, el DISEÑO resulta de vital importancia, ya que se toman las decisiones que determinan el éxito o fracaso del almacén.
Contextualización Selección del diseño La solución de diseño final se selecciona en base a la intuición, al juicio, y principalmente a la experiencia de cada diseñador (Gu et al. 2010). El proceso que finaliza con la identificación de una solución específica no es claro.
Agenda Contextualización Proyecto RAFUWARE Resultados Tecnun Resultados ITA (casos prácticos) Conclusiones
Proyecto RAFUWARE Presentación Proyecto RAFUWARE : the Robust and Adaptive FUture WAREhouse. Desarrollado por Tecnun en colaboración con el ITA, financiado por el Ministerio de Economía y Competitividad (DPI2011-26653).
Proyecto RAFUWARE Objetivos Objetivo general: Generar y validar un nuevo marco/modelo de análisis, diseño y planificación de almacenes y sus operaciones, basado en los conceptos de robustez, flexibilidad y adaptabilidad, buscando la creación de almacenes de referencia mundial, perfectamente integrados en Cadenas de Suministro ágiles y robustas.
Proyecto RAFUWARE Objetivos O1. Crear un marco/modelo para el análisis y diseño de almacenes robustos, flexibles y adaptativos soportado en técnicas avanzadas de modelado y optimización. O2. Crear metodologías/herramientas para gestionar y planificar almacenes robustos, flexibles y adaptativos. O3. Validar mediante simulación en un laboratorio de pruebas el prototipo para ajustar y mejorar el marco/modelo y las herramientas asociadas. O4.Validar el marco/modelo y las herramientas asociadas mediante experimentación industrial.
Agenda Contextualización Proyecto RAFUWARE Resultados Tecnun Resultados ITA (casos prácticos) Conclusiones
Resultados del proyecto RAFUWARE Elementos a diseñar Los productos que llegan a un almacén pasan por una serie de pasos llamados procesos. Estos procesos necesitan recursos como medios, equipos y personal para poder operar. Finalmente, estos recursos se organizan de diferentes formas para poder hacer la operativa lo más eficiente posible (Rouwenhorst et al. 2000) 1. Procesos 2. Recursos 3. Organización
Docks and zones scheduling Docks and zones scheduling Commands Storage systems order ( STOCK AND MANIPULATION) ROSS-DOCKING by rticle ( STOCK BUT ITH MANIPULATION) (Packing list) MANUAL RECEPTION COMBINED DOCK AND ZONES SHIPPING outsourcing Track load type Resultados del proyecto RAFUWARE Modelo RAFUWARE INFORMATIC FULL TRACK Stockholding level WALKING VEHICLES Reception WALKING VEHICLES LESS-THAN- CONTAINER LOAD CROSS-DOCKING by order ( STOCK AND outsourcing MANIPULATION) article ( STOCK BUT WITH MANIPULATION) order ( STOCK AND MANIPULATION) article ( STOCK BUT WITH MANIPULATION) (electronic EDI) PRE-RECEPTION RECEPTION COMBINED DOCK AND ZONES SHIPPING Loading Pattern Shipping (Packing list) MANUAL SOFTWARE INFORMATIC WITH BASIC SOFTWARE (volume and loading pattern ) WITH ADVANCE SOFTWARE (loading sequence and unloading time) Stockholding level order ( STOCK AND MANIPULATION) article ( STOCK BUT WITH MANIPULATION) (Packing list) MANUAL Stock-holding level (electronic EDI) PRE-RECEPTION Stock-holding level INFORMATIC (electronic EDI) PRE-RECEPTION Storage systems AUTOMATIC Storage systems AUTOMATIC PARTS TO PARTS TO PICKER CLASS-BASED Storage strategy CLASS-BASED Storage strategy Storage FAMILY GROUPING CONTAINER CLOSEST OPEN LOCATION RANDOM Organization Resources UNIT FEFO, LIFO, FIFO criterion Storage Almacenaje KIT DEDICATED BOX UNIQUE ZONE Shared Decisions Put-away Storage - Picking Shared Decisions Reception - Shipping PALLET outsourcing SKUs FORWARD PICK AREA CLASS-BASED Worker zone assignment CONTAINER Zoning CLOSEST OPEN LOCATION RANDOM FAMILY GROUPING UNIT FEFO, LIFO, FIFO criterion KIT DEDICATED BOX UNIQUE ZONE outsourcing PALLET Order release mode Worker zone assignment Batching and sorting MULTI-ZONE MULTI-ZONE Storage systems ONE ZONE CONTINUOUS BY ARTICLE AUTOMATIC outsourcing DISCRETE TECHLOGY AIDED BY ORDER BY ZONE Put-away OPTIMAL Routing REPACKAGING PARTS TO PICKER NEEDED HEURISTICS SAME SKU FOR RECEPTION AND SKUs FORWARD PICK Storage systems AREA CLASS-BASED ONE ZONE AUTOMATIC PARTS TO PICKER TECHLOGY AIDED TECHLOGY AIDED TECHLOGY AIDED Worker zone assignment Zoning DIRECT JOINT PUT-AWAY AND PICKING (dual or multiple command) PICKING (single command) HEURISTICS DISCRETE Order release mode WALKING VEHICLES OPTIMAL DIRECTED PUT-AWAY Order release (single mode command) SAME SKU FOR AND SHIPPING UNIQUE AND PICKING ZONE Worker zone CONTINUOUS assignment Picking zoning Order Picking Put-away principles Routing WALKING VEHICLES FORWARD PICK AREA MULTI-ZONE REPACKAGING NEEDED MULTI-ZONE Repackaging ONE ZONE CONTINUOUS Repackaging AUTOMATIC PARTS TO PICKER DISCRETE TECHLOGY AIDED Storage systems ONE ZONE AUTOMATIC TECHN AIDED PARTS TO PICKER
Resultados del proyecto RAFUWARE Medición de la complejidad La complejidad de los procesos de flujo de material - derivada de una combinación de factores - es la que condiciona la gestión. El diseño de un almacén debería comenzar por analizar La complejidad del almacén se calcula mediante el Warehouse activity profiling (Frazelle. 2002b) Líneas por orden Cantidad por línea Unidades de manipulación Número de referencias factores que aumentan la complejidad
Resultados del proyecto RAFUWARE Rendimiento del almacén El rendimiento es el resultado de las actividades llevadas acabo en el almacén y se mide en términos de: Productividad 1 2 Calidad de los pedios El rendimiento de un almacén puede mejorarse si se definen las operativas y los métodos correctos (Aminoff et al. 2002, Tompkins et al. 2010).
Playas de recepción Playas de expedición Zonificación basada en rendimiento Zonificación basada en las características del producto Resultados del proyecto RAFUWARE Mejores prácticas de diseño físico y operativo Zonificar Estrategia de almacenaje Preparación agrupada Artículos Congelado Ambiente Frío Inflamable Regular Peligroso Alto valor Valor regular o bajo Basado en temperatura Basado en composición química Basado en valor Cliente 1 Cliente 2 Cliente n Familia 1 Familia 2 Familia n Basado en clientes Basado en familias Picking por pedido Picking list 1 = Pedido 1 Picking list 2 = Pedido 2 Picking list 3 = Pedido 3. =.. Picking list n = Pedido m Pedido 1 0 ----- X 0------- Y 0---- Z 0 --- Y 0 ------ Extracción agrupada Picking list 1 = Pedido 1 + Pedido 2 +.. Picking list 2 = Pedido 3 + Pedido 4 +.. Picking list 3 = Pedido 5 + Pedido 6 +.... = +. +. Picking list n = Pedido n + Pedido m + Golden zone Silver zone Bronze zone Basado en rotaciones Mecanizar o automatizar Ciclos combinados Cross-docking Entrada Salida Ubicación 1 En carga En vacío Ubicación 2 En carga A B C A B C C 1 C 2 C 3 B 1 B 2 B 3 A 1 A 2 A 1 C 1 B 1 A 1 A 3 A 2 A 3 C 2 B 2 A 2 C 3 B 3 A 3
Docks and zones scheduling Docks and zones scheduling Commands Docks and zones scheduling Discrete replenishment Continuous replenishment Commands Discrete replenishment Continuous replenishment Commands Discrete replenishment Continuous replenishment Resultados del proyecto RAFUWARE Recopilatorio de soluciones de diseño Complexity level Designsolution Performance Complexity Lines per order: 100-1000; Volume per order (items per line): less than 10; Storage unit inventory (items): level 100-1000; Storage unit: unit. Complexity Lines per order: 100-1000; Volume per order (items per line): less than 10; Storage unit inventory (items): level 100-1000; Storage unit: unit. Lines per order: 100-1000; Volume per order (items per line): less than 10; Storage unit Reception inventory (items): Put-away 100-1000; Storage unit: unit. Reception OPTIMAL Stock-holding PARTS TO PICKER level AS/RS S-shape Repackaging order ( STOCK AND Storage systems Miniload Return MANIPULATION) Routing VLM Mid-point REPACKAGING NEEDED AUTOMATIC Carrousel Largest-gap Worker zone Shuttles Combined SAME SKU FOR assignment HEURISTICS article ( STOCK BUT OPTIMAL RECEPTION AND Stock-holding WITH MANIPULATION) PARTS TO PICKER Conventional Reception Put-away level AS/RS S-shape Repackaging MULTI-ZONE Narrow aisle order ( STOCK AND Miniload Return Progressive Push-back MANIPULATION) Storage systems VLM Mid-point REPACKAGING NEEDED Synchronized Dynamic Routing Storage ONE ZONE Pallet truck Carrousel Largest-gap AUTOMATIC WALKING VEHICLES Worker zone One worker Hand truck Shuttles Combined Reach trucks SAME SKU FOR Various Pallet jack assignment Counterbalanced lift trucks HEURISTICS article ( STOCK BUT RECEPTION AND Waking stacker OPTIMAL (Packing list) Order picker Stock-holding WITH MANIPULATION) Conventional outsourcing WALKING VEHICLES Compact shuttle MANUAL PARTS TO PICKER AGVs level MULTI-ZONE Narrow aisle AS/RS S-shape Repackaging Progressive Push-back Conveyors order ( STOCK AND Miniload Return DIRECT Cranes INFORMATIC Synchronized Dynamic MANIPULATION) VLM outsourcing Storage Mid-point REPACKAGING NEEDED ONE ZONE Pallet truck (electronic EDI) One Storage worker systems Hand truck WALKING VEHICLES Carrousel Largest-gap Reach Storage trucks Worker zone DISCRETE Shuttles Combined Various Pallet jack PRE-RECEPTION Counterbalanced lift trucks SAME SKU FOR assignment units RECEPTION Waking stacker (Packing list) HEURISTICS Order picker TECHLOGY article ( STOCK BUT RECEPTION AND PALLET DIRECTED outsourcing WALKING VEHICLES Compact shuttle AIDED WITH MANIPULATION) MANUAL Conventional AGVs CONTINUOUS CONTAINER PUT-AWAY MULTI-ZONE Narrow aisle AUTOMATIC Conveyors TECHLOGY AIDED Progressive Push-back DIRECT Cranes INFORMATIC Order release BOX Put-to-light (single command) outsourcing Synchronized Dynamic Storage ONE ZONE mode (electronic EDI) Pallet truck PARTS TO PICKER Bar code Put-away WALKING VEHICLES One Storage worker systems Hand truck DISCRETE Reach Storage trucks KIT RFID PRE-RECEPTION Various Pallet jack units principles RECEPTION Counterbalanced lift trucks Waking stacker TECHLOGY UNIT Families PALLET DIRECTED (Packing list) Order picker outsourcing Turnovers JOINT PUT-AWAY AND WALKING VEHICLES AIDED CONTINUOUS MANUAL PICKING (dual or Compact shuttle CONTAINER COMBINED PUT-AWAY Safety AGVs AUTOMATIC multiple command) DOCK AND UNIQUE ZONE FORWARD Clients Conveyors TECHLOGY AIDED Designsolution COMBINED CONTINUOUS TO PARTS Safety PICKING (dual or ZONES Order release (single command) DIRECT BOX Cranes PICK AREA INFORMATIC CLASS-BASED Put-to-light outsourcing Balanced docks and AUTOMATED modevehicles Bar code DEDICATED Put-away (electronic EDI) PARTS TO PICKER Storage systems Storage DISCRETE KIT zones RFID CLOSEST OPEN LOCATION Balanced principles PRE-RECEPTION units UNIT Families Zoning RECEPTION TECHLOGY and RANDOM PALLET DIRECTED Turnovers JOINT PUT-AWAY AND Storage systems PICKING PICKER AIDED workers FAMILY GROUPING CONTAINER PUT-AWAY AUTOMATIC DOCK AND UNIQUE ZONE FORWARD Clients multiple command) (single command) TECHLOGY AIDED Designsolution FAMILY GROUPING ZONES Order release PICK AREA CLASS-BASED FEFO, LIFO, FIFO criterion AUTOMATIC BOX Balanced docks and Put-to-light (single command) DEDICATED mode PARTS TO PICKER zones Material Bar code handling Put-away CLASS-BASED KIT CLOSEST OPEN LOCATION PARTS TO PICKER Balanced RFID SHIPPING principles Zoning Routing Storage strategy AS/RS UNIT and Families RANDOM PICKING Miniload S-shape OPTIMAL workers Turnovers JOINT PUT-AWAY AND Storage systems VLM Return COMBINED Safety PICKING (dual or Stock-holding (single command) Worker zone Carrousel Mid-point DOCK AND UNIQUE ZONE FORWARD Clients multiple command) FEFO, LIFO, FIFO criterion level Shuttles order ( STOCK AND assignment Largest-gap ZONES PICK AREA CLASS-BASED AUTOMATIC Combined Balanced docks and MANIPULATION) DEDICATED CLASS-BASED Conventional HEURISTICS MULTI-ZONE REPACKAGING Repackaging zones PARTS TO PICKER CLOSEST OPEN LOCATION SHIPPING Routing Balanced Progressive Narrow aisle Storage strategy AS/RS Zoning NEEDED article ( STOCK BUT and RANDOM Miniload S-shape Synchronized Push-back SAME SKU FOR WITH MANIPULATION) OPTIMAL Storage systems PICKING ONE ZONE workers VLM Return Dynamic AND Stock-holding Track load One worker SHIPPING FAMILY GROUPING Worker zone Carrousel Mid-point level type WALKING VEHICLES (single command) Various Shuttles order ( STOCK AND assignment Largest-gap FEFO, LIFO, FIFO criterion Hand truck FULL TRACK AUTOMATIC Combined MANIPULATION) Pallet jack Pallet truck Mono-destination (Packing list) Organization LESS-THAN- Conventional HEURISTICS REPACKAGING outsourcing Repackaging Waking stacker Reach trucks CLASS-BASED Multi-destination PARTS TO PICKER MULTI-ZONE CONTAINER LOAD MANUAL Narrow aisle NEEDED WALKING VEHICLES Counterbalanced lift trucks SHIPPING Routing Progressive article ( STOCK BUT Storage strategy AS/RS Synchronized Push-back Resources SAME SKU FOR Order picker WITH MANIPULATION) Miniload S-shape OPTIMAL INFORMATIC ONE ZONE Dynamic AND BY ORDER UNIQUE Compact shuttle Track load VLM Return (electronic EDI) One worker AND Stock-holding SOFTWARE Shared Decisions Put-away SHIPPING BY ZONE PICKING ZONE AGVs type WALKING VEHICLES Worker zone Carrousel Mid-point Various PRE-RECEPTION level Storage - Picking Hand truck Conveyors order ( STOCK AND FULL TRACK assignment Shuttles Largest-gap BY ARTICLE Combined Cranes WITH BASIC SOFTWARE Pallet jack Pallet truck MANIPULATION) Organization Pick-and-pass Mono-destination (Packing list) (volume and loading Shared Decisions Reception - Pick-and-sort DISCRETE LESS-THAN- outsourcing Waking stacker Reach trucks pattern ) Batching and TECHLOGY Multi-destination Conventional HEURISTICS CONTAINER LOAD MANUAL MULTI-ZONE REPACKAGING Repackaging Shipping WALKING VEHICLES Counterbalanced lift trucks Progressive Narrow aisle Sort-while-pick Picking zone without storage Resources NEEDED Order picker AIDED article ( STOCK BUT sorting Navigation picking system Picking zone with storage BY ORDER UNIQUE CONTINUOUS INFORMATIC Synchronized Push-back SAME SKU FOR WITH MANIPULATION) Compact shuttle ONE ZONE WITH ADVANCE SOFTWARE TECHLOGY AIDED (electronic EDI) Dynamic AND AND FORWARD PICK AREA Track load outsourcing SOFTWARE One worker Shared Decisions Put-away (loading sequence and BY ZONE SHIPPING PICKING ZONE AGVs Pick-to-light PRE-RECEPTION type WALKING VEHICLES Various Storage - Picking unloading time) Conveyors Pick-to-voice Hand truck BY ARTICLE Cranes FULL TRACK WITH BASIC SOFTWARE Bar code Pallet jack Pallet truck Pick-and-pass (volume and loading Shared Decisions Reception - RFID Picking zoning Pick-and-sort DISCRETE Mono-destination (Packing list) Organization pattern ) Batching and TECHLOGY LESS-THAN- outsourcing Waking stacker Reach trucks Multi-destination Shipping Sort-while-pick Picking zone without storage AIDED CONTAINER LOAD MANUAL WALKING VEHICLES Counterbalanced lift trucks Resources sorting Loading Order picker Navigation picking system Picking zone with storage Order release CONTINUOUS INFORMATIC WITH ADVANCE SOFTWARE BY ORDER UNIQUE Compact shuttle TECHLOGY AIDED Pattern mode FORWARD PICK AREA outsourcing (electronic EDI) (loading sequence and AND Shared Decisions Put-away Pick-to-light SOFTWARE BY ZONE unloading time) PICKING ZONE AGVs PRE-RECEPTION Pick-to-voice Storage - Picking Conveyors BY ARTICLE Cranes Bar code WITH BASIC SOFTWARE Pick-and-pass RFID Picking zoning (volume and loading Shared Decisions Reception - Pick-and-sort DISCRETE Shipping Order Picking pattern ) Batching and TECHLOGY Shipping Sort-while-pick Picking zone without storage AIDED Loading sorting Order release Navigation picking system Picking zone with storage CONTINUOUS Pattern mode WITH ADVANCE SOFTWARE TECHLOGY AIDED FORWARD PICK AREA outsourcing (loading sequence and Pick-to-light unloading time) Loading Pattern Performance Shipping Performance Shipping Productivity: 100 lines/hour; Quality: 0,25%- 0,5% Order lines Picking with errors Productivity: 100 lines/hour; Quality: 0,25%- 0,5% lines with errors Put-away Pick-to-voice Bar code RFID Picking zoning Productivity: 100 lines/hour; Quality: 0,25%- 0,5% Order lines Picking with errors Order release mode Storage systems Routing AUTOMATIC
Docks and zones scheduling Commands Resultados del proyecto RAFUWARE Ejemplo de solución de diseño Reception Storage systems AUTOMATIC Put-away Routing Pocas líneas Mucha cantidad Muchas referencias Unidad de manipulación: Pallets outsourcing Track load type FULL TRACK Mono-destination Multi-destination outsourcing WALKING VEHICLES WALKING VEHICLES LESS-THAN- CONTAINER LOAD article ( STOCK BUT WITH MANIPULATION) order ( STOCK AND MANIPULATION) RECEPTION COMBINED DOCK AND ZONES Balanced docks and zones Balanced and workers SHIPPING SOFTWARE Loading Pattern Shipping (Packing list) MANUAL article ( STOCK BUT WITH MANIPULATION) (Packing list) MANUAL WITH BASIC SOFTWARE (volume and loading pattern ) INFORMATIC WITH ADVANCE SOFTWARE (loading sequence and unloading time) Stock-holding level order ( STOCK AND MANIPULATION) INFORMATIC (electronic EDI) PRE-RECEPTION (electronic EDI) PRE-RECEPTION Stock-holding level Storage Storage systems PALLET AUTOMATIC CONTAINER BOX PARTS TO PICKER KIT UNIT UNIQUE ZONE FORWARD PICK AREA DEDICATED CLOSEST OPEN LOCATION RANDOM FAMILY GROUPING FEFO, LIFO, FIFO criterion CLASS-BASED Storage strategy Organization Resources Shared Decisions Put-away Storage - Picking Shared Decisions Reception - Shipping OPTIMAL PARTS TO PICKER AS/RS S-shape Repackaging Miniload Return VLM Mid-point REPACKAGING NEEDED Carrousel Largest-gap Worker zone Shuttles Combined SAME SKU FOR assignment HEURISTICS RECEPTION AND Conventional MULTI-ZONE Narrow aisle Progressive Push-back Synchronized Dynamic ONE ZONE Pallet truck One worker Hand truck Reach trucks Various Pallet jack Counterbalanced lift trucks Waking stacker Order picker outsourcing WALKING VEHICLES Compact shuttle AGVs Conveyors DIRECT Cranes Storage DISCRETE units TECHLOGY DIRECTED AIDED CONTINUOUS PUT-AWAY TECHLOGY AIDED Order release Put-to-light (single command) mode Bar code Put-away RFID principles Families Turnovers JOINT PUT-AWAY AND Safety PICKING (dual or Clients multiple command) CLASS-BASED Zoning Storage systems PICKING (single command) AUTOMATIC PARTS TO PICKER Routing AS/RS Miniload S-shape OPTIMAL VLM Return Worker zone Carrousel Mid-point assignment Shuttles Largest-gap Combined Conventional HEURISTICS Repackaging MULTI-ZONE REPACKAGING Progressive Narrow aisle NEEDED Synchronized Push-back SAME SKU FOR ONE ZONE Dynamic AND One worker SHIPPING Various Hand truck Pallet jack Pallet truck outsourcing Waking stacker Reach trucks WALKING VEHICLES Counterbalanced lift trucks Order picker BY ORDER UNIQUE Compact shuttle AND BY ZONE PICKING ZONE AGVs Conveyors BY ARTICLE Cranes Pick-and-pass Discrete replenishment Pick-and-sort DISCRETE Continuous replenishment Batching and TECHLOGY Sort-while-pick AIDED Picking zone without storage sorting Navigation picking system Picking zone with storage CONTINUOUS TECHLOGY AIDED FORWARD PICK AREA Pick-to-light Pick-to-voice Bar code RFID Picking zoning Order release mode Order Picking
Docks and zones scheduling Commands Resultados del proyecto RAFUWARE Ejemplo de solución de diseño Reception Storage systems AUTOMATIC Put-away Routing Muchas líneas Poca cantidad por línea Muchas referencias Unidad de manipulación: Unidades outsourcing Track load type FULL TRACK Mono-destination Multi-destination outsourcing WALKING VEHICLES WALKING VEHICLES LESS-THAN- CONTAINER LOAD article ( STOCK BUT WITH MANIPULATION) order ( STOCK AND MANIPULATION) RECEPTION COMBINED DOCK AND ZONES Balanced docks and zones Balanced and workers SHIPPING SOFTWARE Loading Pattern Shipping (Packing list) MANUAL article ( STOCK BUT WITH MANIPULATION) (Packing list) MANUAL WITH BASIC SOFTWARE (volume and loading pattern ) INFORMATIC WITH ADVANCE SOFTWARE (loading sequence and unloading time) Stock-holding level order ( STOCK AND MANIPULATION) INFORMATIC (electronic EDI) PRE-RECEPTION (electronic EDI) PRE-RECEPTION Stock-holding level Storage Storage systems PALLET AUTOMATIC CONTAINER BOX PARTS TO PICKER KIT UNIT UNIQUE ZONE FORWARD PICK AREA DEDICATED CLOSEST OPEN LOCATION RANDOM FAMILY GROUPING FEFO, LIFO, FIFO criterion CLASS-BASED Storage strategy Organization Resources Shared Decisions Put-away Storage - Picking Shared Decisions Reception - Shipping OPTIMAL PARTS TO PICKER AS/RS S-shape Repackaging Miniload Return VLM Mid-point REPACKAGING NEEDED Carrousel Largest-gap Worker zone Shuttles Combined SAME SKU FOR assignment HEURISTICS RECEPTION AND Conventional MULTI-ZONE Narrow aisle Progressive Push-back Synchronized Dynamic ONE ZONE Pallet truck One worker Hand truck Reach trucks Various Pallet jack Counterbalanced lift trucks Waking stacker Order picker outsourcing WALKING VEHICLES Compact shuttle AGVs Conveyors DIRECT Cranes Storage DISCRETE units TECHLOGY DIRECTED AIDED CONTINUOUS PUT-AWAY TECHLOGY AIDED Order release Put-to-light (single command) mode Bar code Put-away RFID principles Families Turnovers JOINT PUT-AWAY AND Safety PICKING (dual or Clients multiple command) CLASS-BASED Zoning Storage systems PICKING (single command) AUTOMATIC PARTS TO PICKER Routing AS/RS Miniload S-shape OPTIMAL VLM Return Worker zone Carrousel Mid-point assignment Shuttles Largest-gap Combined Conventional HEURISTICS MULTI-ZONE REPACKAGING Repackaging Progressive Narrow aisle NEEDED Synchronized Push-back SAME SKU FOR ONE ZONE Dynamic AND One worker SHIPPING Various Hand truck Pallet jack Pallet truck outsourcing Waking stacker Reach trucks WALKING VEHICLES Counterbalanced lift trucks Order picker BY ORDER UNIQUE Compact shuttle AND BY ZONE PICKING ZONE AGVs Conveyors BY ARTICLE Cranes Pick-and-pass Discrete replenishment Pick-and-sort DISCRETE Continuous replenishment Batching and TECHLOGY Sort-while-pick AIDED Picking zone without storage sorting Navigation picking system Picking zone with storage CONTINUOUS TECHLOGY AIDED FORWARD PICK AREA Pick-to-light Pick-to-voice Bar code RFID Picking zoning Order release mode Order Picking
Agenda Contextualización Proyecto RAFUWARE Resultados Tecnun Conclusiones Tecnun Resultados ITA (casos prácticos) Caso1: Diseño de experimentos Caso2: Combinación de algoritmos Caso3: Equipos auto-organizados Conclusiones ITA
There is an enormous gap between the published warehouse research and the practice of warehouse design and operations (Gu et al. 2010) Particularly, the areas of storage assignment and routing appear to have matured the last decade. Few authors address combinations of the decision problems. Yet, this is necessary as there is obvious interdependency in their impact on the order picking objectives (R. de Koster 2007) indicates that a significant need to integrate both approaches (analytical and simulation models) to achieve a greater flexibility in analyzing problems warehouse (Gu et al.2010).
Caso 1: Diseño de experimentos Análisis de la información disponible Caracterización de los flujos Cálculo de alternativas Políticas de almacenamiento Estrategias de preparación de pedidos Datos históricos Diseño de alternativas Simulación: Evaluación de los efectos dinámicos Diseño de experimentos (DOE) Evaluación de las variables mas influyentes Configuración incial Simulación DOE
Caso 1: Diseño de experimentos Analizar datos históricos Realizar experimentos escuchar a los procesos preguntar a los procesos
Caso 2: Combinación de decisiones Métodos híbridos de toma de decisiones considerando varios problemas interrelacionados y adaptados a las condiciones del proceso. URGENCIA vs. EFICIENCIA Acuerdos de nivel de servicio con clientes Equilibrio Minimizar y equilibrar la carga de trabajo
Caso 2: Combinación de decisiones 2a) Integración de algoritmos de optimización (ubicación, picking, dockassignment) para reducir los tiempos de espera.
Caso 2: Combinación de decisiones 2b) Integración de sistemas de previsión de la demanda con modelado de procesos para la planificación dinámica de recursos. Previsión de la demanda Flujo de procesos Planificación
Caso 3: Equipos auto-organizados Modelo Bucket brigades Zone 1 Zone 2 Zone 3 Cómo divido el almacén para minimizar recorridos y tener un equipo de trabajo equilibrado? Zone picking Que hago si tengo que incluir un nuevo operario?
Caso 3: Equipos auto-organizados Modelo Bucket brigades Zone 1 Zone 2 Zone 3 Operarios organizados en equipos, secuenciado de mas lento a mas rápido. Cuando termina un pedido, retrocede hasta que encuentra a su compañero anterior.
Caso 3: Equipos auto-organizados Modelo Bucket brigades Zone 1 Zone 2 Facilidad de aumentar o disminuir los recursos utilizados en la preparación de pedidos. Fomentar el trabajo en equipo con objetivo común.
Agenda Contextualización Proyecto RAFUWARE Resultados Tecnun Resultados ITA (casos prácticos) Conclusiones
Conclusiones Utilidad del modelos RAFUWARE O1. Crear un marco/modelo para el análisis y diseño de almacenes robustos, flexibles y adaptativos soportado en técnicas avanzadas de modelado y optimización. O2. Crear metodologías/herramientas para gestionar y planificar almacenes robustos, flexibles y adaptativos. O3. Validar mediante simulación en un laboratorio de pruebas el prototipo para ajustar y mejorar el marco/modelo y las herramientas asociadas. O4.Validar el marco/modelo y las herramientas asociadas mediante experimentación industrial.
Conclusiones Utilidad del modelos RAFUWARE En un mercado de comercio electrónico, la competitividad depende en gran medida de la eficacia y eficiencia de los procesos logísticos. Una empresa que decida apostar por una estrategia de e- commerce deberá evaluar la necesidad de modificar sus recursos y operativas, ya que lo que funciona correctamente en un escenario tradicional puede no hacerlo en esas nuevas condiciones.
Conclusiones Utilidad del modelos RAFUWARE El marco/modelo RAFUWARE asiste durante el proceso de (re) diseño físico de almacenes, siendo una guía para seleccionar los recursos y operativas adecuados para los procesos de flujo de materiales permitiendo obtener flexibilidad y adaptabilidad, dos atributos clave en un mercado donde el índice de variabilidad de la demanda es elevado
Cómo afrontar los retos de los almacenes del futuro. Resultados del proyecto RAFUWARE Investigadores principales Tecnun: Dra. Claudia Chackelson Dr. Javier Santos Colaboración - ITA : David Ciprés Miriam García