Cómo afrontar los retos de los almacenes del futuro.

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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
Más
Más
Más
Pedidos
Almacenar
Referencias
Servir
Personalizado
Añadir
Valor
Con
Menos
Menos
Plazo de
entrega
Con
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…
el número de
alternativas posibles
1

2
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.
2.
3.
Procesos
Recursos
Organización
Storage systems
Stockholding level
CROSS-DOCKING by
order (NO STOCK AND
NO MANIPULATION)
AUTOMATIC
Resultados del proyecto RAFUWARE
Worker zone
assignment
Modelo RAFUWARE
Reception
Storage
STORAGE
Material handling
equipment
(Packing
MANUAL
list)
CROSS-DOCKING by
order (NO STOCK AND
NO MANIPULATION)
Stockholding level
Worker zone
assignment
RIDING VEHICLES
INFORMATIC
(electronic– EDI)
(Packing
MANUAL
PRE-RECEPTIONlist)
Storage systems
WALKING VEHICLES
RECEPTIONPersonnel and
INDEPENDENT
equipment
INTERNAL
WORKER
outsourcing
EXTERNAL
WORKER
Auxiliaries
RECEPTION
INDEPENDENT
Storage systems
PALLET
CONTAINER
AUTOMATIC
Docks and zones scheduling
Docks and zones scheduling
Material handling
equipment
RANDOM
EXTERNAL
WORKER
Personnel and
CROSS-DOCKING
by order (NO
equipment
STOCK ANDoutsourcing
NO MANIPULATION)
Auxiliaries
CLASS-BASED
Zoning
UNIQUE ZONE
FEFO, LIFO, FIFO criterion
CLASS-BASED
NO
SOFTWARE
Stock-holding
level
FAMILY GROUPING
Organization
INFORMATIC
WITH BASIC SOFTWARE
SOFTWARE (loading
sequence and unloading
time)
Shipping
Storage strategy
(electronic– EDI)
PRE-RECEPTION
Auxiliaries
Resources
Auxiliaries
PICKING
INDEPENDENT
(single
command)
Routing
OPTIMAL
Storage systems
HEURISTICS
PICKER TO PARTS
ONE ZONE
INTERNAL
WORKER
EXTERNAL
WORKER
SAME SKU FOR
STORAGE AND
SHIPPING
BY ARTICLE
Batching and
sor ting
REPACKAGING
NEEDED
Repackaging
AUTOMATIC
WALKING VEHICLES
BY ORDER
RIDING VEHICLES
BY ZONE
Shared Decisions Put-away
Storage - Picking
Shared Decisions Reception Shipping
JOINT PUT-AWAY
AND PICKING (dual
or multiple
command)
Zoning
MULTI-ZONE
Personnel and
equipment
outsourcing
TECHNOLOGY
AIDED
principles
PARTS TO PICKER
FEFO, LIFO, FIFO criterion
CLASS-BASED
(volume and loading pattern )
Stock-holding
level WITH ADVANCE
Loading
Pattern
DEDICATED
FORWARD PICK
Storage systems
AREA
CLASS-BASED
AUTOMATIC
CLOSEST OPEN LOCATION
Worker zone
RANDOM
assignment
Storage strategy
Material handling
equipment
DIRECTED
Order release
Put-away
mode
Order release
mode
FAMILY GROUPING
(Packing list)
MANUAL
LESS-THANCONTAINER LOAD
INTERNAL
WORKER
CROSS-DOCKING by
article (NO STOCK BUT
WITH MANIPULATION)
DEDICATED
STORAGE
FULL TRACK
NO
TECHNOLOGY
PUT-AWAY
AIDED
INDEPENDENT
(single
TECHNOLOGY
command)
AIDED
CONTINUOUS
PICK
UNITFORWARD
AREA
PICKER TO PARTS
CLOSEST OPEN LOCATION
CONTINUOUS
DISCRETE
CONTAINER
NO
TECHN
AIDED
AUTOMATED VEHICLES
DIRECT
KIT
UNIT
DISCRETE
RIDING VEHICLES
UNIQUE ZONE
CROSS-DOCKING by order (NO
STOCK AND NO MANIPULATION)
WALKING VEHICLES
KIT
PICKER TO PARTS
COMBINED
DOCK AND
ZONES
CROSS-DOCKING by
article (NO STOCK BUT
WITH MANIPULATION)
RIDING VEHICLES
SHIPPING
INDEPENDENT
PARTS TO PICKER
SHIPPING
INDEPENDENT
AUTOMATED VEHICLES
Track
load type
PARTS TO PICKER
EXTERNAL
WORKER
WALKING VEHICLES
EXTERNAL
WORKER
PALLET
BOX
BOX
COMBINED
DOCK AND
ZONES
INTERNAL
WORKER
SKUs
AUTOMATIC
Auxiliaries
Repackaging
INTERNAL
SAME SKU FOR
RECEPTION ANDWORKER
STORAGE
ONE ZONE
SKUs
Personnel and
equipment
outsourcing
INFORMATIC
(electronic– EDI)
PRE-RECEPTION
REPACKAGING
NEEDED
MULTI-ZONE
Storage
STORAGE
ONE ZONE
OPTIMAL
Personnel and
PARTS TO PICKER
equipment
HEURISTICS
outsourcing
PICKER TO PARTS
Almacenaje
MULTI-ZONE
Routing
AUTOMATIC
CROSS-DOCKING by
article (NO STOCK BUT
WITH MANIPULATION)
AUTOMATED VEHICLES
PICKER TO PARTS
Put-away
Storage systems
Commands
CROSS-DOCKING by
article (NO STOCK BUT
WITH MANIPULATION)
PARTS TO PICKER
NO
TECHNOLOGY DISCRETE
AIDED
UNIQUE
STORAGE AND
PICKING ZONE
AUTOMATED VEHICLES
Worker
zoneFORWARD PICK
CONTINUOUS
TECHNOLOGY
assignment AREA
AIDED
Auxiliaries
Order release
mode
PARTS TO PICKER
Material handling
equipment
Picking
zoning
Order Picking
PICKER TO PARTS
MULTI-ZONE
ONE ZONE
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…
factores que aumentan la complejidad

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
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:
1

Productividad
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).
Resultados del proyecto RAFUWARE
Mejores prácticas de diseño físico y operativo
Zonificar
Estrategia de almacenaje
Preparación agrupada
Ambiente
Inflamable
Regular
Alto valor
Frío
Basado en temperatura
Peligroso
Basado en composición
química
Valor regular o bajo
Picking por pedido
Picking list 1 = Pedido 1
Picking list 2 = Pedido 2
Picking list 3 = Pedido 3
…….
=
…..
Picking list n = Pedido m
Basado en valor
Cliente 1
Cliente 2
…
Cliente n
Basado en clientes
Familia 1
Familia 2
…
Familia n
Basado en familias
Golden zone
Silver zone
Bronze zone
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 + …
Basado en rotaciones
Mecanizar o automatizar
Ciclos combinados
Ubicación 1
En carga
Entrada
En vacío
Cross-docking
A1
A
B
Ubicación 2
Salida
C
En carga
A
A2
B1
B2
B
C1
C
C2
C3
A1
A3
A2
B3
A3
Playas de expedición
Congelado
Playas de recepción
Zonificación
basada en
rendimiento
Zonificación
basada en las
características
del producto
Artículos
C1 B1 A1
C2 B2 A2
C3 B3 A3
Resultados del proyecto RAFUWARE
Recopilatorio de soluciones de diseño
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 inventory (items):
Complexity
Complexity
level
100-1000; Storage unit: unit.
Lines per order: 100-1000; Volume per order (items per line): less than 10; Storage unit
inventory (items):
Reception
level
100-1000; Storage unit: unit.
Put-away
Storage systems
Reception
Material handling
equipment
CROSS-DOCKING by
order (NO STOCK AND
NO MANIPULATION)
Put-away
Stock-holding
level
Storage systems
Reception
Material handling
equipment
CROSS-DOCKING by
order (NO STOCK AND
NO MANIPULATION)
Material handling
equipment
CROSS-DOCKING by
order (NO STOCK AND
NO MANIPULATION)
Stock-holding
level
RIDING VEHICLES
STORAGE
CROSS-DOCKING by
article (NO STOCK BUT
WITH MANIPULATION)
solution
Material handling
equipment
AUTOMATED VEHICLES
RIDING VEHICLES
Track load
type
WALKING VEHICLES
FULL TRACK
•Mono-destination
•Multi-destination
LESS-THANCONTAINER LOAD
EXTERNAL
WORKER
Personnel and
equipment outsourcing
INTERNAL
WORKER
•Own handling
equipment
•Rented handling
equipment
(electronic– EDI)
PRE-RECEPTION
Personnel and
equipment outsourcing
Auxiliaries
INTERNAL
WORKER
•Own handling
equipment
•Rented handling
equipment
PICKER TO PARTS
•Conventional
•Narrow aisle
•Push-back
•Dynamic
ONE ZONE
•One
worker systems
Storage
•Various
Personnel and
equipment outsourcing
MULTI-ZONE
•Progressive
•Synchronized
INTERNAL
WORKER
•Own handling
equipment
•Rented handling
equipment
•Pallet truck
•Hand truck
•ReachStorage
trucks
•Pallet jack
•Counterbalanced lift trucks
units
•Waking stacker
•Order picker
PALLET
WALKING VEHICLES
•Compact shuttle
•AGVs
CONTAINER
RIDING VEHICLES
•Conveyors
•Cranes
DIRECT
O rder release
BOX
AUTOMATED VEHICLES
EXTERNAL
WORKER
AUTOMATIC
ONE ZONE
•One worker
•Various
•Hand truck
•Pallet jack
•Waking stacker
WALKING VEHICLES
EXTERNAL
WORKER
CONTINUOUS
DIRECT
DISCRETE
NO
TECHNOLOGY
AIDED
DIRECTED
PUT-AWAY
INDEPENDENT
(single command)
INTERNAL
WORKER
•Own handling
equipment
•Rented handling
equipment
INFORMATIC
Design-
solution
Commands
Personnel and
equipment outsourcing
Shipping
Loading
Pattern
Shipping
Performance
Performance
REPACKAGING NEEDED INFORMATIC
SAME SKU FOR
RECEPTION
RECEPTION
AND
INDEPENDENT
STORAGE
MULTI-ZONE
•Progressive
•Synchronized
Repackaging
REPACKAGING NEEDED
SAME SKU FOR
RECEPTION AND
STORAGE
Repackaging
REPACKAGING NEEDED
SAME SKU FOR
RECEPTION AND
STORAGE
Commands
Design-
solution
Design-
Storage
Repackaging
Docks and zones scheduling
EXTERNAL
WORKER
Docks and zones scheduling
INTERNAL
WORKER
•Own handling
equipment
•Rented handling
equipment
(Packing list)
MANUAL
•S-shape
•Return
•Mid-point
•Largest-gap
•Combined
HEURISTICS
Storage
PICKER TO PARTS
•Conventional
•Narrow aisle
•Push-back
•Dynamic
Commands
WALKING VEHICLES
EXTERNAL
WORKER
Storage
•S-shape
EXTERNAL
•Return
WORKER
•Mid-point
•Largest-gap
•Combined
HEURISTICS
Worker zone
assignment
•S-shape
•Return
•Mid-point
•Largest-gap
•Combined
HEURISTICS
•Pallet truck
•Reach trucks
•Counterbalanced lift trucks
•Order picker
•Compact shuttle
•AGVs
RIDING VEHICLES
•Conveyors
•Cranes
AUTOMATED VEHICLES
Material handling
equipment
TECHNOLOGY AIDED
•Put-to-light
mode
•Pallet truck
•Bar code
Put-away
DISCRETE
PARTS
TO PICKER
•Hand truck
KIT
•ReachStorage
trucks
• RFID
Material handling
NO
principles
PRE-RECEPTION
•Pallet jack
•Various
units
•Counterbalanced
lift trucks
Personnel and
RECEPTION
•Families
TECHNOLOGY
equipment
Auxiliaries
•Waking stacker PALLET•Order picker
UNIT
DIRECTED
JOINT PUT-AWAY AND
(Packing list)
INDEPENDENT
•Turnovers
AIDED
equipment outsourcing
WALKING
VEHICLES
CONTINUOUS
•Compact shuttle
INTERNAL
PICKER TO PARTS
PICKING (dual or
EXTERNAL
MANUAL
•Safety
PUT-AWAY
•AGVs
Auxiliaries WORKER
CONTAINER
COMBINED
AUTOMATIC
multiple
command)
WORKER
RIDING VEHICLES
UNIQUE
ZONE
INDEPENDENT
•Clients
FORWARD
•Conveyors
TECHNOLOGY AIDED
DOCK AND
•Own handling
O rder release
(single command)
PICK AREA
•Cranes
DIRECT
CLASS-BASED
ZONES
•Put-to-light
BOX
INFORMATIC
equipment
DEDICATED
modeVEHICLES
AUTOMATED
•Balanced docks and
•Bar code
Put-away
•Rented handling
PARTS TO PICKER
KIT
(electronic– EDI)
zones
DISCRETE
Storage systems
• RFID
Storage
equipment
CLOSEST OPEN LOCATION
principles
Material handling
NO
•Balanced
PRE-RECEPTION
Zoning
•Families
units
Auxiliaries
UNIT
RECEPTION
TECHNOLOGY
RANDOM JOINT PUT-AWAY AND
equipment
equipment
and
DIRECTED
PICKING
•Turnovers
PALLET
Storage systems
INDEPENDENT
workers
PICKER AIDED
TO PARTS
PICKING (dual or
INDEPENDENT
•Safety
CONTINUOUS
COMBINED
FAMILY GROUPING
PUT-AWAY
Auxiliaries
multiple command)
CONTAINER
UNIQUE ZONE FORWARD
(single command)
•Clients
AUTOMATIC
DOCK AND
INDEPENDENT
TECHNOLOGY AIDED
PICK AREA
FEFO, LIFO, FIFO criterion
CLASS-BASED
ZONES
AUTOMATIC
O rder release
(single command)
•Put-to-light
BOX
DEDICATED
•Balanced docks and
mode
•Bar code
Material
handling
Put-away
CLASS-BASED
zones
PARTS TO PICKER
PARTS TO PICKER
KIT
CLOSEST OPEN LOCATION
•
RFID
SHIPPING
Routing
•Balanced
equipment
principles
Zoning
•AS/RS
Storage strategy
INDEPENDENT
•Families
RANDOM
equipment and
Auxiliaries
UNIT
•Miniload
•S-shape
PICKING
OPTIMAL
Storage
systems
JOINT
PUT-AWAY
AND
•Turnovers
workers
•VLM
•Return
INDEPENDENT
PICKER TO PARTS
PICKING (dual or
FAMILY GROUPING
Stock-holding
•Safety
COMBINED
•Mid-point
•Carrousel
(single command)
Worker zone
multiple command)
AUTOMATED VEHICLES
UNIQUE ZONE FORWARD
•Clients
CROSS-DOCKING by
level
DOCK AND
•Shuttles
•Largest-gap
FEFO, LIFO, FIFO criterion
assignment
AUTOMATIC
PICK
AREA
order
(NO
STOCK
AND
CLASS-BASED
ZONES
•Combined
PICKER TO PARTS
DEDICATED
NO MANIPULATION)
•Balanced docks and
Material handling
HEURISTICS
CLASS-BASED
Repackaging
•Conventional
PARTS TO PICKER
MULTI-ZONE
REPACKAGING
zones
SHIPPING
CROSS-DOCKING by
Routing
RIDING VEHICLES
equipment
CLOSEST OPEN LOCATION
•Narrow aisle
•AS/RS
•Progressive
NEEDED
•Balanced
Storage strategy
Zoning
INDEPENDENT
article (NO STOCK BUT
•Push-back
SAME SKU FOR
•Miniload
•Synchronized
•S-shape
RANDOM
OPTIMAL
equipment and
WITH MANIPULATION)
PICKING
ONE ZONE
Storage systems
•Dynamic
STORAGE AND
•VLM
•Return
workers
•One worker
Stock-holding
INDEPENDENT
Track load
SHIPPING
FAMILY GROUPING
•Mid-point
•Carrousel
Worker zone
AUTOMATED VEHICLES
•Various
(single command)
WALKING VEHICLES
CROSS-DOCKING by
level
type
•Shuttles
•Largest-gap
assignment
STORAGE
•Hand truck
order (NO STOCK AND
FEFO, LIFO, FIFO criterion
AUTOMATIC
•Combined
FULL TRACK
•Pallet truck
Personnel and
•Pallet jack
PICKER TO PARTS
NO MANIPULATION)
Organization HEURISTICS
Repackaging INTERNAL
•Reach trucks
(Packing list)
EXTERNAL
•Waking stacker
•Mono-destination
•Conventional
equipment outsourcing
MULTI-ZONE
REPACKAGING
CLASS-BASED
PARTS TO PICKER LESS-THANWORKER
CROSS-DOCKING by
RIDING VEHICLES
WORKER
•Multi-destination
WALKING VEHICLES •Counterbalanced lift trucks
•Narrow aisle
MANUAL
•Progressive
SHIPPING
NEEDED
Routing
CONTAINER LOAD
•AS/RS
article (NO STOCK BUT
•Own handling
Storage strategy
•Order picker
Resources
•Push-back
SAME SKU FOR
•Synchronized
INDEPENDENT
•Miniload
WITH MANIPULATION)
•S-shape
BY ORDER
UNIQUE
ONE ZONE
equipment
OPTIMAL
•Compact shuttle
INFORMATIC
•Dynamic
STORAGE AND
NO
•VLM
•Return
•One worker
STORAGE AND
Track
load
•Rented
handling
(electronic–
EDI)
RIDING VEHICLES •AGVs
EXTERNAL
SHIPPING
Stock-holding
Shared Decisions Put-away
BY ZONE
SOFTWARE
•Mid-point
•Various
PICKING ZONE
•Carrousel
WALKING VEHICLES
Worker zone
equipment
type
WORKER
PRE-RECEPTION
•Conveyors
CROSS-DOCKING by
level
Storage - Picking
STORAGE
•Hand
truck
•Shuttles
•Largest-gap
assignment
BY ARTICLE
•Cranes
INTERNAL
order (NO STOCK AND
FULL TRACK
•Pallet truck
Personnel and
•Pallet jack
•Combined
WITH BASIC SOFTWARE
Discrete replenishment
•Pick-and-pass
NO
Organization
AUTOMATED VEHICLES
PICKER
TO
PARTS
INTERNAL
NO MANIPULATION)
WORKER
•Reach
trucks
(Packing
list)
EXTERNAL
DISCRETE
•Waking
•Mono-destination
(volume and loading equipment outsourcing
Continuous replenishment
Auxiliaries
HEURISTICS
Shared Decisions Reception
- stacker
Repackaging
•Pick-and-sort
LESS-THANTECHNOLOGY
•Conventional
WORKER
MULTI-ZONE
REPACKAGING
Batching and
WORKER
•Own handling
•Multi-destination
WALKING VEHICLES •Counterbalanced lift trucks
MANUAL
pattern )
CROSS-DOCKING by
•Sort-while-pick
Shipping
•Picking
zone
without
storage
CONTAINER LOAD
AIDED
•Narrow
aisle
•Progressive
NEEDED
•Own handling
•Order picker
equipment
Resources
sorting
article (NO STOCK BUT
•Navigation picking system
•Picking zone with storage
Material handling
•Push-back
SAME SKU FOR
•Synchronized Personnel and
BY ORDER
UNIQUE
equipment
CONTINUOUS
•Compact shuttle
•Rented handling
INFORMATIC
WITH MANIPULATION)
ONE
ZONE
WITH ADVANCE SOFTWARE
TECHNOLOGY AIDED
•Dynamic equipment
NO
STORAGE AND
STORAGE AND
FORWARD PICK AREA
equipment
•Rented handling
(electronic– EDI)
RIDING VEHICLES •AGVs
EXTERNAL
•One worker
equipment
outsourcing Shared
Decisions Put-away
BY ZONE
SOFTWARE
SHIPPING (loading sequence and
•Pick-to-light
PICKING ZONE
equipment
WORKER
PRE-RECEPTION
•Various
•Conveyors
unloading time)
Storage - Picking
•Pick-to-voice
BY ARTICLE
STORAGE
•Hand truck
•Cranes
INTERNAL
WITH BASIC SOFTWARE
Discrete replenishment
Auxiliaries •Bar code
•Pick-and-pass
•Pallet truck
Personnel and
•Pallet jack
NO
AUTOMATED VEHICLES
WORKER
Picking zoning
DISCRETE
•RFID
(volume and loading
Continuous replenishment
Organization
Auxiliaries
Shared Decisions Reception
- stacker
INTERNAL
•Pick-and-sort
•Reach trucks
(Packing list)
EXTERNAL
•Waking
TECHNOLOGY
equipment
outsourcing
Batching and
•Own handling
pattern )
WORKER
•Sort-while-pick
Shipping
WORKER
•Picking zone without storage
AIDED
WALKING VEHICLES •Counterbalanced lift trucks
MANUAL
equipment
sorting
O
rder
release
•Own handling
•Navigation
picking
system
•Picking
zone
with
storage
•Order
picker
Resources
Material handling
Loading
CONTINUOUS
•Rented handling
Personnel and
BY ORDER
UNIQUE
equipment
WITH ADVANCE SOFTWARE
•Compact shuttle
mode
TECHNOLOGY AIDED
INFORMATIC
FORWARD PICK AREA
equipment
Pattern
NO
STORAGE AND
equipment outsourcing equipment
•Rented handling
(loading sequence and
(electronic– EDI)
RIDING VEHICLES •AGVs
•Pick-to-light
Shared Decisions Put-away
BY ZONE
SOFTWARE
PICKING ZONE
unloading time)
equipment
•Pick-to-voice
PRE-RECEPTION
•Conveyors
Storage - Picking
BY ARTICLE
•Cranes
Auxiliaries •Bar code
WITH BASIC SOFTWARE
Discrete replenishment
•Pick-and-pass
Picking zoning
•RFID
NO
AUTOMATED VEHICLES
DISCRETE
(volume and loading
Continuous replenishment
Auxiliaries
Shared Decisions Reception •Pick-and-sort
TECHNOLOGY
Batching and
pattern )
•Sort-while-pick
Shipping
•Picking zone without storage
AIDED
O rder release
sorting
Loading
•Navigation picking system
•Picking zone with storage
Material handling
CONTINUOUS
mode
Pattern
WITH ADVANCE SOFTWARE
TECHNOLOGY AIDED
FORWARD PICK AREA
equipment
(loading sequence and
•Pick-to-light
unloading time)
•Pick-to-voice
Auxiliaries •Bar code
Picking zoning
•RFID
STORAGE
Personnel and
equipment outsourcing
(Packing list)
MANUAL
Docks and zones scheduling
RIDING VEHICLES
PARTS TO PICKER
•AS/RS
•Miniload
Personnel and
INTERNAL
equipment outsourcing•VLM
•Carrousel WORKER
Worker zone
•Shuttles •Own handling
assignment
equipment
PICKER
TO PARTS
•Rented
handling
•Conventional
equipment
•Narrow aisle
MULTI-ZONE
•Push-back
•Progressive
•Dynamic
•Synchronized
ONE ZONE
(electronic– EDI)
Storage
•One
worker systems
PARTS TO PICKER
•AS/RS
•Miniload
•VLM
•Carrousel
•Shuttles
Worker zone
assignment
PARTS TO PICKER
•AS/RS
•Miniload
•VLM
•Carrousel
•Shuttles
Routing
OPTIMAL
STORAGE
Routing
WALKING VEHICLES
OPTIMAL
WALKING VEHICLES
AUTOMATED VEHICLES
Put-away
RIDING VEHICLES
AUTOMATIC
CROSS-DOCKING by
article (NO STOCK BUT
WITH MANIPULATION)
CROSS-DOCKING by
article (NO STOCK BUT
WITH MANIPULATION)
Storage systems
AUTOMATED VEHICLES
OPTIMAL
AUTOMATIC
AUTOMATED VEHICLES
Stock-holding
level
Routing
AUTOMATIC
Shipping
Performance
Orderlines
Picking
Productivity: 100 lines/hour; Quality: 0,25%- 0,5%
with errors
O rder release
mode
Orderlines
Picking
Productivity: 100 lines/hour; Quality: 0,25%- 0,5%
with errors
Productivity: 100 lines/hour; Quality: 0,25%- 0,5% lines with errors
Order Picking
Resultados del proyecto RAFUWARE
Ejemplo de solución de diseño
Put-away
Reception
Storage systems
Routing
AUTOMATIC
Material handling
equipment
CROSS-DOCKING by
order (NO STOCK AND
NO MANIPULATION)
OPTIMAL
Stock-holding
level
AUTOMATED VEHICLES
Worker zone
assignment
CROSS-DOCKING by
article (NO STOCK BUT
WITH MANIPULATION)
RIDING VEHICLES
MULTI-ZONE
•Progressive
•Synchronized
Storage
STORAGE
WALKING VEHICLES
Personnel and
equipment outsourcing
(Packing list)
MANUAL
Personnel and
equipment outsourcing
•
INFORMATIC
(electronic– EDI)
Storage systems
Storage
units
PRE-RECEPTION
RECEPTION
INDEPENDENT
Track load
type
KIT
UNIT
PICKER TO PARTS
COMBINED
DOCK AND
ZONES
•Balanced docks and
zones
•Balanced
equipment and
workers
UNIQUE ZONE
DEDICATED
CLOSEST OPEN LOCATION
RANDOM
FORWARD
PICK AREA
MULTI-ZONE
•Progressive
•Synchronized
STORAGE
EXTERNAL
WORKER
Personnel and
equipment outsourcing
Organization
(Packing list)
MANUAL
NO
SOFTWARE
Resources
INFORMATIC
WITH BASIC SOFTWARE
(volume and loading
pattern )
(electronic– EDI)
PRE-RECEPTION
Auxiliaries
Shared Decisions Put-away
Storage - Picking
Shared Decisions Reception Shipping
PICKER TO PARTS
•Conventional
•Narrow aisle
•Push-back
•Dynamic
SAME SKU FOR
STORAGE AND
SHIPPING
•Hand truck
•Pallet jack
•Waking stacker
WALKING VEHICLES
Personnel and
equipment outsourcing
INTERNAL
EXTERNAL
WORKER
WORKER
•Own handling
equipment
•Rented handling
BY ZONE
equipment
BY ARTICLE
•Pick-and-pass
•Pick-and-sort
Batching and
•Sort-while-pick
sorting
•Navigation picking system
Auxiliaries
Shipping
Routing
•S-shape
OPTIMAL
•Return
•Mid-point
•Largest-gap
•Combined
HEURISTICS
ONE ZONE
•One worker
•Various
WITH ADVANCE SOFTWARE
(loading sequence and
unloading time)
Loading
Pattern
Put-away
principles
JOINT PUT-AWAY AND
PICKING (dual or
multiple command)
PICKING
INDEPENDENT
(single command)
PARTS TO PICKER
•AS/RS
•Miniload
•VLM
•Carrousel
•Shuttles
Worker zone
assignment
CROSS-DOCKING by
article (NO STOCK BUT
WITH MANIPULATION)
INTERNAL
WORKER
•Own handling
equipment
•Rented handling
equipment
TECHNOLOGY AIDED
•Put-to-light
•Bar code
• RFID
Material handling
equipment
DIRECTED
PUT-AWAY
INDEPENDENT
(single command)
AUTOMATIC
CLASS-BASED
CROSS-DOCKING by
order (NO STOCK AND
NO MANIPULATION)
LESS-THANCONTAINER LOAD
DIRECT
NO
TECHNOLOGY
AIDED
Storage systems
Storage strategy
Stock-holding
level
•Pallet truck
•Reach trucks
•Counterbalanced lift trucks
•Order picker
•Compact shuttle
•AGVs
RIDING VEHICLES
•Conveyors
•Cranes
AUTOMATED VEHICLES
Zoning
FEFO, LIFO, FIFO criterion
SHIPPING
INDEPENDENT
SAME SKU FOR
RECEPTION AND
STORAGE
DISCRETE
FAMILY GROUPING
WALKING VEHICLES
FULL TRACK
•Mono-destination
•Multi-destination
EXTERNAL
WORKER
Auxiliaries
•Families
•Turnovers
•Safety
•Clients
CLASS-BASED
Repackaging
REPACKAGING NEEDED
•Hand truck
•Pallet jack
•Waking stacker
WALKING VEHICLES
O rder release
mode
BOX
RIDING VEHICLES
ONE ZONE
•One worker
•Various
CONTINUOUS
CONTAINER
AUTOMATIC
PARTS TO PICKER
AUTOMATED VEHICLES
PICKER TO PARTS
•Conventional
•Narrow aisle
•Push-back
•Dynamic
PALLET
Auxiliaries
Material handling
equipment
INTERNAL
WORKER
•Own handling
equipment
•Rented handling
equipment
•S-shape
•Return
•Mid-point
•Largest-gap
•Combined
HEURISTICS
Commands
Pocas líneas
Mucha cantidad
Muchas
referencias
Unidad de
manipulación:
Pallets
EXTERNAL
WORKER
Docks and zones scheduling
•
•
•
INTERNAL
WORKER
•Own handling
equipment
•Rented handling
equipment
PARTS TO PICKER
•AS/RS
•Miniload
•VLM
•Carrousel
•Shuttles
UNIQUE
STORAGE AND
PICKING ZONE
BY ORDER
NO
DISCRETE
TECHNOLOGY
AIDED
TECHNOLOGY AIDED
•Pick-to-light
•Pick-to-voice
•Bar code
•RFID
CONTINUOUS
REPACKAGING
NEEDED
•Pallet truck
•Reach trucks
•Counterbalanced lift trucks
•Order picker
•Compact shuttle
RIDING VEHICLES •AGVs
Discrete replenishment
Continuous replenishment
•Picking zone without storage
•Picking zone with storage
FORWARD PICK AREA
Picking zoning
O rder release
mode
Order Picking
Repackaging
•Conveyors
•Cranes
AUTOMATED VEHICLES
Material handling
equipment
Resultados del proyecto RAFUWARE
Ejemplo de solución de diseño
Put-away
Reception
Storage systems
Routing
AUTOMATIC
Material handling
equipment
CROSS-DOCKING by
order (NO STOCK AND
NO MANIPULATION)
OPTIMAL
Stock-holding
level
AUTOMATED VEHICLES
Worker zone
assignment
CROSS-DOCKING by
article (NO STOCK BUT
WITH MANIPULATION)
RIDING VEHICLES
MULTI-ZONE
•Progressive
•Synchronized
Storage
STORAGE
WALKING VEHICLES
Personnel and
equipment outsourcing
(Packing list)
MANUAL
Personnel and
equipment outsourcing
•
•
INFORMATIC
(electronic– EDI)
Storage systems
Storage
units
PRE-RECEPTION
RECEPTION
INDEPENDENT
Track load
type
KIT
UNIT
PICKER TO PARTS
COMBINED
DOCK AND
ZONES
•Balanced docks and
zones
•Balanced
equipment and
workers
UNIQUE ZONE
DEDICATED
CLOSEST OPEN LOCATION
RANDOM
FORWARD
PICK AREA
MULTI-ZONE
•Progressive
•Synchronized
STORAGE
EXTERNAL
WORKER
Personnel and
equipment outsourcing
INTERNAL
WORKER
•Own handling
equipment
•Rented handling
equipment
Organization
(Packing list)
MANUAL
NO
SOFTWARE
Resources
INFORMATIC
WITH BASIC SOFTWARE
(volume and loading
pattern )
(electronic– EDI)
PRE-RECEPTION
Auxiliaries
Shared Decisions Put-away
Storage - Picking
Shared Decisions Reception Shipping
PICKER TO PARTS
•Conventional
•Narrow aisle
•Push-back
•Dynamic
SAME SKU FOR
STORAGE AND
SHIPPING
•Hand truck
•Pallet jack
•Waking stacker
WALKING VEHICLES
Personnel and
equipment outsourcing
INTERNAL
EXTERNAL
WORKER
WORKER
•Own handling
equipment
•Rented handling
BY ZONE
equipment
BY ARTICLE
•Pick-and-pass
•Pick-and-sort
Batching and
•Sort-while-pick
sorting
•Navigation picking system
Auxiliaries
Shipping
Routing
•S-shape
OPTIMAL
•Return
•Mid-point
•Largest-gap
•Combined
HEURISTICS
ONE ZONE
•One worker
•Various
WITH ADVANCE SOFTWARE
(loading sequence and
unloading time)
Loading
Pattern
Put-away
principles
JOINT PUT-AWAY AND
PICKING (dual or
multiple command)
PICKING
INDEPENDENT
(single command)
PARTS TO PICKER
•AS/RS
•Miniload
•VLM
•Carrousel
•Shuttles
Worker zone
assignment
CROSS-DOCKING by
article (NO STOCK BUT
WITH MANIPULATION)
LESS-THANCONTAINER LOAD
TECHNOLOGY AIDED
•Put-to-light
•Bar code
• RFID
Material handling
equipment
DIRECTED
PUT-AWAY
INDEPENDENT
(single command)
AUTOMATIC
CLASS-BASED
CROSS-DOCKING by
order (NO STOCK AND
NO MANIPULATION)
•Cranes
AUTOMATED VEHICLES
DIRECT
NO
TECHNOLOGY
AIDED
Storage systems
Storage strategy
Stock-holding
level
•Pallet truck
•Reach trucks
•Counterbalanced lift trucks
•Order picker
•Compact shuttle
•AGVs
RIDING VEHICLES
•Conveyors
Zoning
FEFO, LIFO, FIFO criterion
SHIPPING
INDEPENDENT
SAME SKU FOR
RECEPTION AND
STORAGE
DISCRETE
FAMILY GROUPING
WALKING VEHICLES
FULL TRACK
•Mono-destination
•Multi-destination
EXTERNAL
WORKER
Auxiliaries
•Families
•Turnovers
•Safety
•Clients
CLASS-BASED
Repackaging
REPACKAGING NEEDED
•Hand truck
•Pallet jack
•Waking stacker
WALKING VEHICLES
O rder release
mode
BOX
RIDING VEHICLES
ONE ZONE
•One worker
•Various
CONTINUOUS
CONTAINER
AUTOMATIC
PARTS TO PICKER
AUTOMATED VEHICLES
PICKER TO PARTS
•Conventional
•Narrow aisle
•Push-back
•Dynamic
PALLET
Auxiliaries
Material handling
equipment
INTERNAL
WORKER
•Own handling
equipment
•Rented handling
equipment
•S-shape
•Return
•Mid-point
•Largest-gap
•Combined
HEURISTICS
Commands
Muchas líneas
Poca cantidad por
línea
Muchas
referencias
Unidad de
manipulación:
Unidades
EXTERNAL
WORKER
Docks and zones scheduling
•
•
INTERNAL
WORKER
•Own handling
equipment
•Rented handling
equipment
PARTS TO PICKER
•AS/RS
•Miniload
•VLM
•Carrousel
•Shuttles
UNIQUE
STORAGE AND
PICKING ZONE
BY ORDER
NO
DISCRETE
TECHNOLOGY
AIDED
TECHNOLOGY AIDED
•Pick-to-light
•Pick-to-voice
•Bar code
•RFID
CONTINUOUS
REPACKAGING
NEEDED
•Pallet truck
•Reach trucks
•Counterbalanced lift trucks
•Order picker
•Compact shuttle
RIDING VEHICLES •AGVs
Discrete replenishment
Continuous replenishment
•Picking zone without storage
•Picking zone with storage
FORWARD PICK AREA
Picking zoning
O rder release
mode
Order Picking
Repackaging
•Conveyors
•Cranes
AUTOMATED VEHICLES
Material handling
equipment
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
“escuchar a
los
procesos”
Realizar
experimentos
“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
Minimizar y
equilibrar la
carga de
trabajo
Acuerdos de
nivel de
servicio con
clientes
Equilibrio
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”
• ¿Cómo divido el almacén
para minimizar recorridos
y tener un equipo de
trabajo equilibrado?
Zone 1
Zone 2
Zone 3
“Zone picking”
¿Que hago si tengo que incluir un
nuevo operario?
Caso 3: Equipos auto-organizados
Modelo “Bucket brigades”
• Operarios
organizados en
equipos ,
secuenciado de mas
lento a mas rápido.
Zone
1
Zone 2
Zone 3
• 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 ecommerce 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
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