Diapositive by alicejenny

VIEWS: 90 PAGES: 15

									    Ferrero Belgium optimizes its
 warehouse thanks to the Warehouse
Management System of Generix Group
Introduction

■         S&V Management Consultants
    > Deliver ‘state-of-the-art’ advice in Supply Chain Strategy and
      Performance and in Supply Chain Process Excellence.




■ Ferrero
    > Distribution center in Ternat
    > +/- 600 references
    > 4.200 pallet locations
        − 3.600 bulk locations
        − 620 pick locations
    > 12 operators
    > WMS:
                                                                       2
Project goal
■ Define the future warehouse organization (Ternat)

   > Layout, Storage capacity, Optimal Material flow

   > Roles & Responsibilities, KPI’s

   > Benchmarking (efficiency & cost)

   > Provide a sustainable solution towards future volumes & profile changes




                                                                               3
Project Approach
■ Interviews

■ Observations

■ Data analysis



Project Timing
■ Analysis phase: 2008

■ Programming phase: Started December 2008

■ Testing phase: February 2009

■ Go live: May 2009

                                             4
  Prioritizing improvement actions
IMPACT                                                                                           MOQ per OL
                   Split case picking-          Balance Inbound flows                 Balance         1
                 Pallet transfer to dock       based on outbound flows Case-Pallet pick               2           Completed
                                1                        1                               1
                                5                        0            OR                 1                     1st priority actions
    high
                                                                                                                 Related actions

                                                            Scrapping on
€ 15 000                                                     quintale base
                                                                                                                 CSC actions
           Pallet volume calculation
                                             1 step receiving                                                  Planning actions
                   1                                            21
 medium            6                                    7                                                       Out of scope
               Floor storage                                    Balancing inbound
              6-                                                 Production plants
              9                                                        1
€ 5 000
                                                        1                    3
                           20            4              4                                    1
    low                                                                                      3
                       5                       2                                 17


                                                                                                              EFFORT
                        low                        medium                                high

                                                                                                                                      5
Selected actions



1. Split case picking and pallet transfer to dock

2. One step receiving – One step loading

3. Floor storage




                                                    6
1. Split case picking & pallet transfer to dock

AS IS process                           TO BE process
■ Order picker prepares picking         ■ Order picker prepares picking
  pallet                                  pallet
                                        ■ Order picker wraps picking pallet
■ Order picker wraps picking
  pallet                                ■ Order picker brings pallet to dock
                                          X1, X2, X3
■ Order picker brings pallet to
                                                         OR
  dock
                                        ■ Order picker brings pallet to buffer
                                          zone picking
                                        ■ Servant brings pallet to dock



     Goal: Order pickers do order picking and bring pallets to buffer zone OR
        bring pallets to docks close to order picking zone
     Gain: Use of empty rides servants after replenishment process (from bulk to
        picking zone)
                                                                                 7
              1. Split case picking & pallet transfer to dock
                                                                                                                                                      +5m




                                                                                                                                                                             10,4 m
                                                                                                                                              Stock PLV
5,9 m




         Detail/                                                                                                                                                          22,5 m
          SPE
                                                                                                                                             Picking
                                                                                                                                            Picking zone:

                                                                                                                                   Bat
         Bur




                                                                                                                                                                          30 m
                                                                                                                                                                          + 38 m
                          E       E       E       E       E       E       E       E       E       E       E         E         E               Stockage
                              S       S       S       S       S       S       S       S       S       S       S           S




                                                                                                                                                                          5,7 m
          Empty pallets




                                                                                                                                            Floor storage
                                                                                                                                            Extension
                                                                                                                                              1120 m²




                                                                                                                                                          Floor storage
15,8 m




                                                                                                                                                                          14 m
                                                                                                                                         18,4 m

                                              Zone de Reception / Expedition                                              Buffer

                                                                                                                  4,8 m
                                                                                                                          Picking
                                                                                                                          Bureau
                                                                                                                          4,8 m
         2,4 m
                                                                                                                                                           9m
                                                                                                                    AS IS flow
                                                                                                                  TO BE flow                                                          8
2. One step receiving – one step loading
 AS IS process receiving                TO BE process receiving
 ■ Unloading truck: put pallets on      ■ Scan pallet in truck
    dock                                ■ Bring pallet to bulk drop zone in
 ■ Control of pallets
 ■ Scan pallets
 ■ Bring pallets to bulk drop zone in
                                        TO BE process loading
 AS IS process loading
                                        ■ Scan pallet at bulk drop zone out
 ■ Bring pallets from bulk drop zone
                                        ■ Load pallet into truck
    out to dock
 ■ Control of pallets
 ■ Scan pallet
 ■ Load pallets into truck

    Goal: Avoid putting pallets on docks during put away process especially
       when unloading full truck of 1 product
    Gain: No control action: Put pallets immediately in front of bulk zone
                                                                              9
                          2. One step receiving – one step loading
                                                                                                                                                       +5m




                                                                                                                                                                              10,4 m
                                                                                                                                               Stock PLV
5,9 m




         Detail/                                                                                                                                                           22,5 m
          SPE
                                                                                                                                              Picking
                                                                                                                                             Picking zone:

                                                                                                                                    Bat
         Bur




                                                                                                                                                                           30 m
                                                                                                                                                                           + 38 m
                           E       E       E       E       E       E       E       E       E       E       E         E         E               Stockage
                               S       S       S       S       S       S       S       S       S       S       S           S




                                                                                                                                                                           5,7 m
          Empty pallets




                                                                                                                                             Floor storage
                                                                                                                                             Extension
                                                                                                                                               1120 m²




                                                                                                                                                           Floor storage
15,8 m




                                                                                                                                                                           14 m
                                                                                                                                          18,4 m

                                               Zone de Reception / Expedition                                              Buffer

                                                                                                                   4,8 m
                                                                                                                           Picking
                                                                                                                           Bureau
                                                                                                                           4,8 m
         2,4 m
                                                                                                                                                            9m
                                                                                                                     AS IS flow
                                                                                                                   TO BE flow                                                          10
                           2-step                  1-step
3. Floor storage

AS IS process                             TO BE process
■ Scan pallet                             ■ Scan pallet
■ Put pallet from dock into bulk          ■ Put pallets from dock (or from
  drop zone in                              truck) into floor storage zone
■ Put pallet in bulk                      ■ Get pallet out of floor storage
■ Get pallet out of bulk                    zone
■ Scan pallet                             ■ Bring pallet to dock
■ Bring pallet from bulk drop
  zone out to dock


     Goal: Avoid putting pallets in bulk which will we delivered to customers within
        a few days
     Gain: Pallets movements in and out of bulk

                                                                                11
              3. Floor storage
                                                                                                                                                      +5m




                                                                                                                                                                             10,4 m
                                                                                                                                              Stock PLV
5,9 m




         Detail/                                                                                                                                                          22,5 m
          SPE
                                                                                                                                             Picking
                                                                                                                                            Picking zone:

                                                                                                                                   Bat
         Bur




                                                                                                                                                                          30 m
                                                                                                                                                                          + 38 m
                          E       E       E       E       E       E       E       E       E       E       E         E         E               Stockage
                              S       S       S       S       S       S       S       S       S       S       S           S




                                                                                                                                                                          5,7 m
          Empty pallets




                                                                                                                                            Floor storage
                                                                                                                                            Extension
                                                                                                                                              1120 m²




                                                                                                                                                          Floor storage
15,8 m




                                                                                                                                                                          14 m
                                                                                                                                         18,4 m

                                              Zone de Reception / Expedition                                              Buffer

                                                                                                                  4,8 m
                                                                                                                          Picking
                                                                                                                          Bureau
                                                                                                                          4,8 m
         2,4 m
                                                                                                                                                           9m
                                                                                                                    AS IS flow
                                                                                                                  TO BE flow                                                          12
Improvement actions and their impact

                              Infrastructure   Material Handling   IT   Global Supply
                                   (M²)          Equipment                  chain

Split case picking & pallet
transfer to dock
                                    X                              X


One step receiving – one
step loading
                                                      X            X         X


Floor storage

                                    X                              X




                                                                                        13
Challenges & Conclusions

■ Support needed of total Supply Chain for
  realization of improvement actions
  > One step receiving – loading requires perfect quality SSCC labels
  > Need for cooperation of production plants on
      − Quality SSCC labels
      − Number of SSCC labels per pallet



■ Importance of testing phase

■ Communication/involvement of operators


                                                                    14
Thank you for your attention!

Welcome at stand 72 for coffee and




                                     15

								
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