cómo afrontar los retos de los almacenes del...

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

• Contextualización

• Proyecto RAFUWARE

• Resultados Tecnun

• Resultados ITA (casos prácticos)

• Conclusiones

Agenda

• 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

Pedidos Más Almacenar

Referencias Más Servir

Personalizado Más Añadir

Valor Más

Con

Plazo de

entrega Menos Con

Margen de

error Menos

Contextualización Aumento de la complejidad

Un nuevo almacén Bajos niveles de servicio y/o altos costes

Redefinición de las funciones

Cambio en la Complejidad de los procesos

Contextualización Motivos para (re)diseñar un almacén

El DISEÑO de almacenes es un problema complejo…

Sin embargo, el DISEÑO resulta de vital importancia, ya que se toman las decisiones que determinan el éxito o fracaso del almacén.

la fuerte interacción entre los factores involucrados

el número de alternativas posibles

1 2

Contextualización Importancia 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.

Contextualización Selección del diseño





• Conclusiones

Agenda

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 Presentación

• 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.

Proyecto RAFUWARE Objetivos





• Conclusiones

Agenda

• 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

Resultados del proyecto RAFUWARE Elementos a diseñar

Resultados del proyecto RAFUWARE Modelo RAFUWARE

CONTAINER

FAMILY GROUPING

CLOSEST OPEN LOCATION

Personnel and

equipment

outsourcing

INTERNAL

WORKER

Stock-

holding levelCROSS-DOCKING by

order (NO STOCK AND

NO MANIPULATION)

STORAGE

EXTERNAL

WORKER

RECEPTION

INDEPENDENT

Do

ck

s a

nd

zo

ne

s s

ch

ed

uli

ng

COMBINED

DOCK AND

ZONES

Worker zone

assignment

Order release

mode Put-away

principles

DIRECT

DIRECTED

DISCRETE

CONTINUOUS

ONE ZONE

PUT-AWAY

INDEPENDENT

(single

command)

Routing

HEURISTICS

OPTIMAL

TECHNOLOGY

AIDED

Co

mm

an

ds

Picking

zoning

UNIQUE

STORAGE AND

PICKING ZONE

PICKING

INDEPENDENT

(single

command)

JOINT PUT-AWAY

AND PICKING (dual

or multiple

command)

Loading

Pattern

SHIPPING

INDEPENDENT

Reception

Shipping Order Picking

Put-away

Auxiliaries

Organization

Resources

Shared Decisions Put-away

Storage - Picking

Shared Decisions Reception -

Shipping

SKUs

PALLET

UNIT

Storage strategy

BOX

Repackaging

SAME SKU FOR

RECEPTION AND

STORAGE

Zoning

UNIQUE ZONE FORWARD PICK

AREA

CLASS-BASEDDEDICATED

RANDOM

CLASS-BASED

Storage

Storage systems

AUTOMATIC

PARTS TO PICKER

PICKER TO PARTS

REPACKAGING

NEEDED

Material handling

equipment

AUTOMATED VEHICLES

WALKING VEHICLES

RIDING VEHICLES

Auxiliaries

PRE-RECEPTION

(electronic– EDI)

INFORMATIC

MANUAL(Packing

list)

CROSS-DOCKING by

article (NO STOCK BUT

WITH MANIPULATION)

NO

SOFTWARE

WITH BASIC SOFTWARE

(volume and loading pattern )

WITH ADVANCE

SOFTWARE (loading

sequence and unloading

time)

Track

load type

LESS-THAN-

CONTAINER LOAD

FULL TRACK

BY ORDER

BY ZONE

BY ARTICLE

Batching and

sorting

KIT

FEFO, LIFO, FIFO criterion

INTERNAL

WORKER

EXTERNAL

WORKER

Stock-holding

levelCROSS-DOCKING by order (NO

STOCK AND NO MANIPULATION)

STORAGE

CROSS-DOCKING by


WITH MANIPULATION)

Auxiliaries

PRE-RECEPTION

(electronic– EDI)INFORMATIC

MANUAL

(Packing list)

Material handling

equipment

Storage systems

AUTOMATIC

PARTS TO PICKER

PICKER TO PARTS

Storage systems

AUTOMATIC

PARTS TO PICKER

PICKER TO PARTS

INTERNAL

WORKEREXTERNAL

WORKER

NO

TECHNOLOGY

AIDED

Auxiliaries

Worker zone

assignment

ONE ZONE

Personnel and

equipment

outsourcing

Order release

mode

DISCRETE

CONTINUOUSFORWARD PICK

AREAMaterial handling

equipment

SAME SKU FOR

STORAGE AND

SHIPPING

REPACKAGING

NEEDED

Routing

HEURISTICS

OPTIMAL

AUTOMATED VEHICLES

WALKING VEHICLES

RIDING VEHICLES

Material handling

equipment

AUTOMATED VEHICLES

WALKING VEHICLES

RIDING VEHICLES

Personnel and

equipment

outsourcing

Repackaging

Personnel and

equipment

outsourcing

INTERNAL

WORKER

EXTERNAL

WORKER

TECHNOLOGY

AIDED

NO

TECHNOLOGY

AIDED

AUTOMATED VEHICLES

WALKING VEHICLES

RIDING VEHICLES

MULTI-ZONE

MULTI-ZONE

CONTAINER

FAMILY GROUPING


Personnel and

equipment

outsourcing

INTERNAL

WORKER

Stock-

holding levelCROSS-DOCKING by

order (NO STOCK AND

NO MANIPULATION)

STORAGE

EXTERNAL

WORKER

RECEPTION

INDEPENDENT

Do

ck

s a

nd

zo

ne

s s

ch

ed

uli

ng

COMBINED

DOCK AND

ZONES

Worker zone

assignment

Order release

mode Put-away

principles

DIRECT

DIRECTED

DISCRETE

CONTINUOUS

ONE ZONE

PUT-AWAY

INDEPENDENT

(single

command)

Routing

HEURISTICS

OPTIMAL

TECHNOLOGY

AIDED

Co

mm

an

ds

Picking

zoning

UNIQUE

STORAGE AND

PICKING ZONE

PICKING

INDEPENDENT

(single

command)

JOINT PUT-AWAY

AND PICKING (dual

or multiple

command)

Loading

Pattern

SHIPPING

INDEPENDENT

Reception


Put-away

Auxiliaries

Organization

Resources


Storage - Picking


Shipping

SKUs

PALLET

UNIT

Storage strategy

BOX

Repackaging

SAME SKU FOR

RECEPTION AND

STORAGE

Zoning

UNIQUE ZONE FORWARD PICK

AREA

CLASS-BASEDDEDICATED

RANDOM

CLASS-BASED

Storage

Storage systems

AUTOMATIC

PARTS TO PICKER

PICKER TO PARTS

REPACKAGING

NEEDED

Material handling

equipment

AUTOMATED VEHICLES

WALKING VEHICLES

RIDING VEHICLES

Auxiliaries

PRE-RECEPTION

(electronic– EDI)

INFORMATIC

MANUAL(Packing

list)

CROSS-DOCKING by


WITH MANIPULATION)

NO

SOFTWARE

WITH BASIC SOFTWARE

(volume and loading pattern )

WITH ADVANCE

SOFTWARE (loading

sequence and unloading

time)

Track

load type

LESS-THAN-

CONTAINER LOAD

FULL TRACK

BY ORDER

BY ZONE

BY ARTICLE

Batching and

sorting

KIT


INTERNAL

WORKER

EXTERNAL

WORKER

Stock-holding

levelCROSS-DOCKING by order (NO

STOCK AND NO MANIPULATION)

STORAGE

CROSS-DOCKING by


WITH MANIPULATION)

Auxiliaries

PRE-RECEPTION


MANUAL

(Packing list)

Material handling

equipment

Storage systems

AUTOMATIC

PARTS TO PICKER

PICKER TO PARTS

Storage systems

AUTOMATIC

PARTS TO PICKER

PICKER TO PARTS

INTERNAL

WORKEREXTERNAL

WORKER

NO

TECHNOLOGY

AIDED

Auxiliaries

Worker zone

assignment

ONE ZONE

Personnel and

equipment

outsourcing

Order release

mode

DISCRETE

CONTINUOUSFORWARD PICK

AREAMaterial handling

equipment

SAME SKU FOR

STORAGE AND

SHIPPING

REPACKAGING

NEEDED

Routing

HEURISTICS

OPTIMAL

AUTOMATED VEHICLES

WALKING VEHICLES

RIDING VEHICLES

Material handling

equipment

AUTOMATED VEHICLES

WALKING VEHICLES

RIDING VEHICLES

Personnel and

equipment

outsourcing

Repackaging

Personnel and

equipment

outsourcing

INTERNAL

WORKER

EXTERNAL

WORKER

TECHNOLOGY

AIDED

NO

TECHNOLOGY

AIDED

AUTOMATED VEHICLES

WALKING VEHICLES

RIDING VEHICLES

MULTI-ZONE

MULTI-ZONE

Almacenaje

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 Medición de la complejidad

El rendimiento es el resultado de las actividades llevadas acabo en el

almacén y se mide en términos de:

El rendimiento de un almacén puede mejorarse si se definen las operativas y los métodos correctos (Aminoff et al. 2002, Tompkins et al. 2010).

Productividad Calidad de los pedios 1 2

Resultados del proyecto RAFUWARE Rendimiento del almacén

Resultados del proyecto RAFUWARE Mejores prácticas de diseño físico y operativo

Zonificar Estrategia de almacenaje Preparación agrupada

Mecanizar o automatizar Ciclos combinados Cross-docking

A

B

C

A3

A2

A1

A1B1C1

A2B2C2

A3B3C3

B3

B2

C3

C2 Pla

ya

s d

e e

xp

ed

ició

n

A

B

CPla

ya

s d

e r

ece

pció

n

B1

C1

A1

A2

A3

En carga

En vacío

Ubicación 1

Entrada

Salida

Ubicación 2

En carga

Artículos

Congelado Ambiente Frío

Inflamable Regular Peligroso

Alto valor Valor regular o bajo

Cliente 1 Cliente 2 Cliente n

Familia 1 Familia 2 Familia n

Golden zone Silver zone Bronze zone

Basado en temperatura

Basado en composición

química

Basado en valor

Basado en clientes

Basado en familias

Basado en rotaciones

…

…

Zo

nif

ica

ció

n

ba

sa

da

en

la

s

ca

racte

rísti

ca

s

de

l pro

du

cto

Zo

nif

ica

ció

n

ba

sa

da

en

ren

dim

ien

to

Picking por pedido

Picking list 1 = Pedido 1



……. = …..

Picking list n = Pedido m

Extracción agrupada

Picking list 1 = Pedido 1 + Pedido 2 + …..



…….. = …… + ……. + ….

Picking list n = Pedido n + Pedido m + …

Pedido 1

0 ----- X

0------- Y

0---- Z

0 --- Y

0 ------

Complexity

level

Lines per order: 100-1000; Volume per order (items per line): less than 10; Storage unit inventory (items):

100-1000; Storage unit: unit.

Design-

solution

Performance Productivity: 100 lines/hour; Quality: 0,25%- 0,5% lines with errors

CONTAINER

FAMILY GROUPING


Personnel and

equipment outsourcing INTERNAL

WORKER

Stock-holding

levelCROSS-DOCKING by

order (NO STOCK AND

NO MANIPULATION)

STORAGE

EXTERNAL

WORKER

RECEPTION

INDEPENDENT

Do

cks a

nd z

on

es

sch

ed

ulin

g

COMBINED

DOCK AND

ZONES

•Balanced docks and

zones

•Balanced

equipment and

workers

Worker zone

assignment

Order release

mode Put-away

principles

DIRECT

DIRECTED

DISCRETE

CONTINUOUS

ONE ZONE

PUT-AWAY

INDEPENDENT

(single command)

Routing

HEURISTICS

OPTIMAL

TECHNOLOGY AIDED

•Put-to-light

•Bar code

•RFID

•One worker

•Various

•S-shape

•Return

•Mid-point

•Largest-gap

•Combined

Co

mm

an

ds

Picking zoning

UNIQUE

STORAGE AND

PICKING ZONE

PICKING

INDEPENDENT

(single command)

•Pick-to-light

•Pick-to-voice

•Bar code

•RFID

•Picking zone without storage

•Picking zone with storage

•Pick-and-pass

•Pick-and-sort

•Sort-while-pick

•Navigation picking system

JOINT PUT-AWAY AND

PICKING (dual or

multiple command)

Discrete replenishment

Continuous replenishment

Loading

Pattern

SHIPPING

INDEPENDENT

Reception


Put-away

Auxiliaries

Organization

Resources


Storage - Picking


Shipping

Storage

unitsPALLET

UNIT

Storage strategy

BOX

Repackaging

SAME SKU FOR

RECEPTION AND

STORAGE

Zoning

UNIQUE ZONE FORWARD

PICK AREA CLASS-BASEDDEDICATED

RANDOM

CLASS-BASED

Storage

•Families

•Turnovers

•Safety

•Clients

Storage systems

AUTOMATIC

PARTS TO PICKER

PICKER TO PARTS

REPACKAGING NEEDED

Material handling

equipment

AUTOMATED VEHICLES

WALKING VEHICLES

•AGVs

•Conveyors

•Cranes

RIDING VEHICLES

•Hand truck

•Pallet jack

•Waking stacker

•Pallet truck

•Reach trucks

•Counterbalanced lift trucks

•Order picker

•Compact shuttle

Auxiliaries

PRE-RECEPTION

(electronic– EDI)

INFORMATIC

MANUAL

(Packing list)

CROSS-DOCKING by


WITH MANIPULATION)

NO

SOFTWARE

WITH BASIC SOFTWARE

(volume and loading

pattern )

WITH ADVANCE SOFTWARE

(loading sequence and

unloading time)

Track load

type

LESS-THAN-

CONTAINER LOAD

FULL TRACK

•Mono-destination

•Multi-destination

BY ORDER

BY ZONE

BY ARTICLE

Batching and

sorting

KIT


•Own handling

equipment

•Rented handling

equipment

INTERNAL

WORKER

EXTERNAL

WORKER

•Own handling

equipment

•Rented handling

equipment

Stock-holding


order (NO STOCK AND

NO MANIPULATION)

STORAGE

CROSS-DOCKING by


WITH MANIPULATION)

Auxiliaries

PRE-RECEPTION


MANUAL

(Packing list)

Material handling

equipment

Storage systems

AUTOMATIC

PARTS TO PICKER

PICKER TO PARTS

•AS/RS

•Miniload

•VLM

•Carrousel

•Shuttles

•Conventional

•Narrow aisle

•Push-back

•Dynamic

Storage systems

AUTOMATIC

PARTS TO PICKER

PICKER TO PARTS

•AS/RS

•Miniload

•VLM

•Carrousel

•Shuttles

•Conventional

•Narrow aisle

•Push-back

•Dynamic

INTERNAL

WORKEREXTERNAL

WORKER

•Own handling

equipment

•Rented handling

equipmentNO

TECHNOLOGY

AIDED

Auxiliaries

Worker zone

assignment

ONE ZONE•One worker

•Various

Personnel and

equipment outsourcing

Order release

mode

DISCRETE

CONTINUOUSFORWARD PICK AREA

Material handling

equipment

SAME SKU FOR

STORAGE AND

SHIPPING

REPACKAGING

NEEDED

Routing

HEURISTICS

OPTIMAL•S-shape

•Return

•Mid-point

•Largest-gap

•Combined

AUTOMATED VEHICLES

WALKING VEHICLES

RIDING VEHICLES

Material handling

equipment

AUTOMATED VEHICLES

WALKING VEHICLES

RIDING VEHICLES

Personnel and


Repackaging

Personnel and


INTERNAL

WORKEREXTERNAL

WORKER

•Own handling

equipment

•Rented handling

equipment

TECHNOLOGY AIDED

NO

TECHNOLOGY

AIDED

AUTOMATED VEHICLES

WALKING VEHICLES

•AGVs

•Conveyors

•Cranes

RIDING VEHICLES

•Hand truck

•Pallet jack

•Waking stacker

•Pallet truck

•Reach trucks


•Order picker

•Compact shuttle

MULTI-ZONE•Progressive

•Synchronized


•Synchronized

Complexity

level



Design-

solution


CONTAINER

FAMILY GROUPING


Personnel and


WORKER

Stock-holding


order (NO STOCK AND

NO MANIPULATION)

STORAGE

EXTERNAL

WORKER

RECEPTION

INDEPENDENT

Do

cks a

nd z

on

es

sch

ed

ulin

g

COMBINED

DOCK AND

ZONES


zones

•Balanced

equipment and

workers

Worker zone

assignment

Order release

mode Put-away

principles

DIRECT

DIRECTED

DISCRETE

CONTINUOUS

ONE ZONE

PUT-AWAY

INDEPENDENT

(single command)

Routing

HEURISTICS

OPTIMAL

TECHNOLOGY AIDED

•Put-to-light

•Bar code

•RFID

•One worker

•Various

•S-shape

•Return

•Mid-point

•Largest-gap

•Combined

Co

mm

an

ds

Picking zoning

UNIQUE

STORAGE AND

PICKING ZONE

PICKING

INDEPENDENT

(single command)

•Pick-to-light

•Pick-to-voice

•Bar code

•RFID



•Pick-and-pass

•Pick-and-sort

•Sort-while-pick


JOINT PUT-AWAY AND

PICKING (dual or

multiple command)



Loading

Pattern

SHIPPING

INDEPENDENT

Reception


Put-away

Auxiliaries

Organization

Resources


Storage - Picking


Shipping

Storage

unitsPALLET

UNIT

Storage strategy

BOX

Repackaging

SAME SKU FOR

RECEPTION AND

STORAGE

Zoning

UNIQUE ZONE FORWARD


RANDOM

CLASS-BASED

Storage

•Families

•Turnovers

•Safety

•Clients

Storage systems

AUTOMATIC

PARTS TO PICKER

PICKER TO PARTS

REPACKAGING NEEDED

Material handling

equipment

AUTOMATED VEHICLES

WALKING VEHICLES

•AGVs

•Conveyors

•Cranes

RIDING VEHICLES

•Hand truck

•Pallet jack

•Waking stacker

•Pallet truck

•Reach trucks


•Order picker

•Compact shuttle

Auxiliaries

PRE-RECEPTION

(electronic– EDI)

INFORMATIC

MANUAL

(Packing list)

CROSS-DOCKING by


WITH MANIPULATION)

NO

SOFTWARE

WITH BASIC SOFTWARE

(volume and loading

pattern )



unloading time)

Track load

type

LESS-THAN-

CONTAINER LOAD

FULL TRACK

•Mono-destination


BY ORDER

BY ZONE

BY ARTICLE

Batching and

sorting

KIT


•Own handling

equipment

•Rented handling

equipment

INTERNAL

WORKER

EXTERNAL

WORKER

•Own handling

equipment

•Rented handling

equipment

Stock-holding


order (NO STOCK AND

NO MANIPULATION)

STORAGE

CROSS-DOCKING by


WITH MANIPULATION)

Auxiliaries

PRE-RECEPTION


MANUAL

(Packing list)

Material handling

equipment

Storage systems

AUTOMATIC

PARTS TO PICKER

PICKER TO PARTS

•AS/RS

•Miniload

•VLM

•Carrousel

•Shuttles

•Conventional

•Narrow aisle

•Push-back

•Dynamic

Storage systems

AUTOMATIC

PARTS TO PICKER

PICKER TO PARTS

•AS/RS

•Miniload

•VLM

•Carrousel

•Shuttles

•Conventional

•Narrow aisle

•Push-back

•Dynamic

INTERNAL

WORKEREXTERNAL

WORKER

•Own handling

equipment

•Rented handling

equipmentNO

TECHNOLOGY

AIDED

Auxiliaries

Worker zone

assignment


•Various

Personnel and


Order release

mode

DISCRETE


Material handling

equipment

SAME SKU FOR

STORAGE AND

SHIPPING

REPACKAGING

NEEDED

Routing

HEURISTICS

OPTIMAL•S-shape

•Return

•Mid-point

•Largest-gap

•Combined

AUTOMATED VEHICLES

WALKING VEHICLES

RIDING VEHICLES

Material handling

equipment

AUTOMATED VEHICLES

WALKING VEHICLES

RIDING VEHICLES

Personnel and


Repackaging

Personnel and


INTERNAL

WORKEREXTERNAL

WORKER

•Own handling

equipment

•Rented handling

equipment

TECHNOLOGY AIDED

NO

TECHNOLOGY

AIDED

AUTOMATED VEHICLES

WALKING VEHICLES

•AGVs

•Conveyors

•Cranes

RIDING VEHICLES

•Hand truck

•Pallet jack

•Waking stacker

•Pallet truck

•Reach trucks


•Order picker

•Compact shuttle


•Synchronized


•Synchronized

Complexity

level



Design-

solution


CONTAINER

FAMILY GROUPING


Personnel and


WORKER

Stock-holding


order (NO STOCK AND

NO MANIPULATION)

STORAGE

EXTERNAL

WORKER

RECEPTION

INDEPENDENT

Do

cks a

nd z

on

es

sch

ed

ulin

g

COMBINED

DOCK AND

ZONES


zones

•Balanced

equipment and

workers

Worker zone

assignment

Order release

mode Put-away

principles

DIRECT

DIRECTED

DISCRETE

CONTINUOUS

ONE ZONE

PUT-AWAY

INDEPENDENT

(single command)

Routing

HEURISTICS

OPTIMAL

TECHNOLOGY AIDED

•Put-to-light

•Bar code

•RFID

•One worker

•Various

•S-shape

•Return

•Mid-point

•Largest-gap

•Combined

Co

mm

an

ds

Picking zoning

UNIQUE

STORAGE AND

PICKING ZONE

PICKING

INDEPENDENT

(single command)

•Pick-to-light

•Pick-to-voice

•Bar code

•RFID



•Pick-and-pass

•Pick-and-sort

•Sort-while-pick


JOINT PUT-AWAY AND

PICKING (dual or

multiple command)



Loading

Pattern

SHIPPING

INDEPENDENT

Reception


Put-away

Auxiliaries

Organization

Resources


Storage - Picking


Shipping

Storage

unitsPALLET

UNIT

Storage strategy

BOX

Repackaging

SAME SKU FOR

RECEPTION AND

STORAGE

Zoning

UNIQUE ZONE FORWARD


RANDOM

CLASS-BASED

Storage

•Families

•Turnovers

•Safety

•Clients

Storage systems

AUTOMATIC

PARTS TO PICKER

PICKER TO PARTS

REPACKAGING NEEDED

Material handling

equipment

AUTOMATED VEHICLES

WALKING VEHICLES

•AGVs

•Conveyors

•Cranes

RIDING VEHICLES

•Hand truck

•Pallet jack

•Waking stacker

•Pallet truck

•Reach trucks


•Order picker

•Compact shuttle

Auxiliaries

PRE-RECEPTION

(electronic– EDI)

INFORMATIC

MANUAL

(Packing list)

CROSS-DOCKING by


WITH MANIPULATION)

NO

SOFTWARE

WITH BASIC SOFTWARE

(volume and loading

pattern )



unloading time)

Track load

type

LESS-THAN-

CONTAINER LOAD

FULL TRACK

•Mono-destination


BY ORDER

BY ZONE

BY ARTICLE

Batching and

sorting

KIT


•Own handling

equipment

•Rented handling

equipment

INTERNAL

WORKER

EXTERNAL

WORKER

•Own handling

equipment

•Rented handling

equipment

Stock-holding


order (NO STOCK AND

NO MANIPULATION)

STORAGE

CROSS-DOCKING by


WITH MANIPULATION)

Auxiliaries

PRE-RECEPTION


MANUAL

(Packing list)

Material handling

equipment

Storage systems

AUTOMATIC

PARTS TO PICKER

PICKER TO PARTS

•AS/RS

•Miniload

•VLM

•Carrousel

•Shuttles

•Conventional

•Narrow aisle

•Push-back

•Dynamic

Storage systems

AUTOMATIC

PARTS TO PICKER

PICKER TO PARTS

•AS/RS

•Miniload

•VLM

•Carrousel

•Shuttles

•Conventional

•Narrow aisle

•Push-back

•Dynamic

INTERNAL

WORKEREXTERNAL

WORKER

•Own handling

equipment

•Rented handling

equipmentNO

TECHNOLOGY

AIDED

Auxiliaries

Worker zone

assignment


•Various

Personnel and


Order release

mode

DISCRETE


Material handling

equipment

SAME SKU FOR

STORAGE AND

SHIPPING

REPACKAGING

NEEDED

Routing

HEURISTICS

OPTIMAL•S-shape

•Return

•Mid-point

•Largest-gap

•Combined

AUTOMATED VEHICLES

WALKING VEHICLES

RIDING VEHICLES

Material handling

equipment

AUTOMATED VEHICLES

WALKING VEHICLES

RIDING VEHICLES

Personnel and


Repackaging

Personnel and


INTERNAL

WORKEREXTERNAL

WORKER

•Own handling

equipment

•Rented handling

equipment

TECHNOLOGY AIDED

NO

TECHNOLOGY

AIDED

AUTOMATED VEHICLES

WALKING VEHICLES

•AGVs

•Conveyors

•Cranes

RIDING VEHICLES

•Hand truck

•Pallet jack

•Waking stacker

•Pallet truck

•Reach trucks


•Order picker

•Compact shuttle


•Synchronized


•Synchronized

Resultados del proyecto RAFUWARE Recopilatorio de soluciones de diseño

Resultados del proyecto RAFUWARE Ejemplo de solución de diseño

CONTAINER

FAMILY GROUPING


Personnel and


WORKER

Stock-holding


order (NO STOCK AND

NO MANIPULATION)

STORAGE

EXTERNAL

WORKER

RECEPTION

INDEPENDENT

Do

cks a

nd z

on

es

sch

ed

ulin

g

COMBINED

DOCK AND

ZONES


zones

•Balanced

equipment and

workers

Worker zone

assignment

Order release

mode Put-away

principles

DIRECT

DIRECTED

DISCRETE

CONTINUOUS

ONE ZONE

PUT-AWAY

INDEPENDENT

(single command)

Routing

HEURISTICS

OPTIMAL

TECHNOLOGY AIDED

•Put-to-light

•Bar code

•RFID

•One worker

•Various

•S-shape

•Return

•Mid-point

•Largest-gap

•Combined

Co

mm

an

ds

Picking zoning

UNIQUE

STORAGE AND

PICKING ZONE

PICKING

INDEPENDENT

(single command)

•Pick-to-light

•Pick-to-voice

•Bar code

•RFID



•Pick-and-pass

•Pick-and-sort

•Sort-while-pick


JOINT PUT-AWAY AND

PICKING (dual or

multiple command)



Loading

Pattern

SHIPPING

INDEPENDENT

Reception


Put-away

Auxiliaries

Organization

Resources


Storage - Picking


Shipping

Storage

unitsPALLET

UNIT

Storage strategy

BOX

Repackaging

SAME SKU FOR

RECEPTION AND

STORAGE

Zoning

UNIQUE ZONE FORWARD


RANDOM

CLASS-BASED

Storage

•Families

•Turnovers

•Safety

•Clients

Storage systems

AUTOMATIC

PARTS TO PICKER

PICKER TO PARTS

REPACKAGING NEEDED

Material handling

equipment

AUTOMATED VEHICLES

WALKING VEHICLES

•AGVs

•Conveyors

•Cranes

RIDING VEHICLES

•Hand truck

•Pallet jack

•Waking stacker

•Pallet truck

•Reach trucks


•Order picker

•Compact shuttle

Auxiliaries

PRE-RECEPTION

(electronic– EDI)

INFORMATIC

MANUAL

(Packing list)

CROSS-DOCKING by


WITH MANIPULATION)

NO

SOFTWARE

WITH BASIC SOFTWARE

(volume and loading

pattern )



unloading time)

Track load

type

LESS-THAN-

CONTAINER LOAD

FULL TRACK

•Mono-destination


BY ORDER

BY ZONE

BY ARTICLE

Batching and

sorting

KIT


•Own handling

equipment

•Rented handling

equipment

INTERNAL

WORKER

EXTERNAL

WORKER

•Own handling

equipment

•Rented handling

equipment

Stock-holding


order (NO STOCK AND

NO MANIPULATION)

STORAGE

CROSS-DOCKING by


WITH MANIPULATION)

Auxiliaries

PRE-RECEPTION


MANUAL

(Packing list)

Material handling

equipment

Storage systems

AUTOMATIC

PARTS TO PICKER

PICKER TO PARTS

•AS/RS

•Miniload

•VLM

•Carrousel

•Shuttles

•Conventional

•Narrow aisle

•Push-back

•Dynamic

Storage systems

AUTOMATIC

PARTS TO PICKER

PICKER TO PARTS

•AS/RS

•Miniload

•VLM

•Carrousel

•Shuttles

•Conventional

•Narrow aisle

•Push-back

•Dynamic

INTERNAL

WORKEREXTERNAL

WORKER

•Own handling

equipment

•Rented handling

equipmentNO

TECHNOLOGY

AIDED

Auxiliaries

Worker zone

assignment


•Various

Personnel and


Order release

mode

DISCRETE


Material handling

equipment

SAME SKU FOR

STORAGE AND

SHIPPING

REPACKAGING

NEEDED

Routing

HEURISTICS

OPTIMAL•S-shape

•Return

•Mid-point

•Largest-gap

•Combined

AUTOMATED VEHICLES

WALKING VEHICLES

RIDING VEHICLES

Material handling

equipment

AUTOMATED VEHICLES

WALKING VEHICLES

RIDING VEHICLES

Personnel and


Repackaging

Personnel and


INTERNAL

WORKEREXTERNAL

WORKER

•Own handling

equipment

•Rented handling

equipment

TECHNOLOGY AIDED

NO

TECHNOLOGY

AIDED

AUTOMATED VEHICLES

WALKING VEHICLES

•AGVs

•Conveyors

•Cranes

RIDING VEHICLES

•Hand truck

•Pallet jack

•Waking stacker

•Pallet truck

•Reach trucks


•Order picker

•Compact shuttle


•Synchronized


•Synchronized

• Pocas líneas • Mucha cantidad • Muchas

referencias • Unidad de

manipulación: Pallets

Resultados del proyecto RAFUWARE Ejemplo de solución de diseño

• Muchas líneas • Poca cantidad por

línea • Muchas

referencias • Unidad de

manipulación: Unidades

CONTAINER

FAMILY GROUPING


Personnel and


WORKER

Stock-holding


order (NO STOCK AND

NO MANIPULATION)

STORAGE

EXTERNAL

WORKER

RECEPTION

INDEPENDENT

Do

cks a

nd z

on

es

sch

ed

ulin

g

COMBINED

DOCK AND

ZONES


zones

•Balanced

equipment and

workers

Worker zone

assignment

Order release

mode Put-away

principles

DIRECT

DIRECTED

DISCRETE

CONTINUOUS

ONE ZONE

PUT-AWAY

INDEPENDENT

(single command)

Routing

HEURISTICS

OPTIMAL

TECHNOLOGY AIDED

•Put-to-light

•Bar code

•RFID

•One worker

•Various

•S-shape

•Return

•Mid-point

•Largest-gap

•Combined

Co

mm

an

ds

Picking zoning

UNIQUE

STORAGE AND

PICKING ZONE

PICKING

INDEPENDENT

(single command)

•Pick-to-light

•Pick-to-voice

•Bar code

•RFID



•Pick-and-pass

•Pick-and-sort

•Sort-while-pick


JOINT PUT-AWAY AND

PICKING (dual or

multiple command)



Loading

Pattern

SHIPPING

INDEPENDENT

Reception


Put-away

Auxiliaries

Organization

Resources


Storage - Picking


Shipping

Storage

unitsPALLET

UNIT

Storage strategy

BOX

Repackaging

SAME SKU FOR

RECEPTION AND

STORAGE

Zoning

UNIQUE ZONE FORWARD


RANDOM

CLASS-BASED

Storage

•Families

•Turnovers

•Safety

•Clients

Storage systems

AUTOMATIC

PARTS TO PICKER

PICKER TO PARTS

REPACKAGING NEEDED

Material handling

equipment

AUTOMATED VEHICLES

WALKING VEHICLES

•AGVs

•Conveyors

•Cranes

RIDING VEHICLES

•Hand truck

•Pallet jack

•Waking stacker

•Pallet truck

•Reach trucks


•Order picker

•Compact shuttle

Auxiliaries

PRE-RECEPTION

(electronic– EDI)

INFORMATIC

MANUAL

(Packing list)

CROSS-DOCKING by


WITH MANIPULATION)

NO

SOFTWARE

WITH BASIC SOFTWARE

(volume and loading

pattern )



unloading time)

Track load

type

LESS-THAN-

CONTAINER LOAD

FULL TRACK

•Mono-destination


BY ORDER

BY ZONE

BY ARTICLE

Batching and

sorting

KIT


•Own handling

equipment

•Rented handling

equipment

INTERNAL

WORKER

EXTERNAL

WORKER

•Own handling

equipment

•Rented handling

equipment

Stock-holding


order (NO STOCK AND

NO MANIPULATION)

STORAGE

CROSS-DOCKING by


WITH MANIPULATION)

Auxiliaries

PRE-RECEPTION


MANUAL

(Packing list)

Material handling

equipment

Storage systems

AUTOMATIC

PARTS TO PICKER

PICKER TO PARTS

•AS/RS

•Miniload

•VLM

•Carrousel

•Shuttles

•Conventional

•Narrow aisle

•Push-back

•Dynamic

Storage systems

AUTOMATIC

PARTS TO PICKER

PICKER TO PARTS

•AS/RS

•Miniload

•VLM

•Carrousel

•Shuttles

•Conventional

•Narrow aisle

•Push-back

•Dynamic

INTERNAL

WORKEREXTERNAL

WORKER

•Own handling

equipment

•Rented handling

equipmentNO

TECHNOLOGY

AIDED

Auxiliaries

Worker zone

assignment


•Various

Personnel and


Order release

mode

DISCRETE


Material handling

equipment

SAME SKU FOR

STORAGE AND

SHIPPING

REPACKAGING

NEEDED

Routing

HEURISTICS

OPTIMAL•S-shape

•Return

•Mid-point

•Largest-gap

•Combined

AUTOMATED VEHICLES

WALKING VEHICLES

RIDING VEHICLES

Material handling

equipment

AUTOMATED VEHICLES

WALKING VEHICLES

RIDING VEHICLES

Personnel and


Repackaging

Personnel and


INTERNAL

WORKEREXTERNAL

WORKER

•Own handling

equipment

•Rented handling

equipment

TECHNOLOGY AIDED

NO

TECHNOLOGY

AIDED

AUTOMATED VEHICLES

WALKING VEHICLES

•AGVs

•Conveyors

•Cranes

RIDING VEHICLES

•Hand truck

•Pallet jack

•Waking stacker

•Pallet truck

•Reach trucks


•Order picker

•Compact shuttle


•Synchronized


•Synchronized




• Conclusiones Tecnun

• Resultados ITA (casos prácticos) • Caso1: Diseño de experimentos

• Caso2: Combinación de algoritmos

• Caso3: Equipos auto-organizados

• Conclusiones ITA

Agenda

… 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).

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)

There is an enormous gap between the published warehouse research and the practice of warehouse design and operations (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

• Simulación: Evaluación de los efectos dinámicos

• Diseño de experimentos (DOE)

• Evaluación de las variables mas influyentes

Datos

históricos

Diseño de

alternativas

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

Minimizar y equilibrar la carga de trabajo

Acuerdos de nivel de servicio con clientes

Equilibrio

Métodos híbridos de toma de decisiones considerando varios problemas interrelacionados y adaptados a las condiciones del proceso.

URGENCIA vs. EFICIENCIA


2a) Integración de algoritmos de optimización (ubicación, picking, dock-assignment) para reducir los tiempos de espera.


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

• ¿Cómo divido el almacén para minimizar recorridos y tener un equipo de trabajo equilibrado?

“Zone picking”

Zone 2 Zone 3 Zone 1

¿Que hago si tengo que incluir un nuevo operario?

Caso 3: Equipos auto-organizados Modelo “Bucket brigades”

Zone 2 Zone 3 Zone

1

• Operarios organizados en equipos , secuenciado de mas lento a mas rápido.

• Cuando termina un pedido, retrocede hasta que encuentra a su compañero anterior.


Zone 2 Zone 1

• Facilidad de aumentar o disminuir los recursos utilizados en la preparación de pedidos.

• Fomentar el trabajo en equipo con objetivo común.






• Conclusiones

Agenda

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.


• 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

cómo afrontar los retos de los almacenes del...

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