Warehousing

Function
Storage in Transit Inventory


Economic Service
Consolidation & Break Bulk - Spot Stocking
Assortment - Full Line Stocking
Postponement - Product Support
Stockpiling - Market Presence
Reverse Logistics
Consolidation & Break Bulk
Reduce Transportation Cost by using
warehouse capability to increase
shipment economic of scale
Consolidation, warehouse receives
materials from number of sources which
combined into a large single shipment
to a specific destination
Break-Bulk, operator receives a single
large shipment and arrange for delivery
to multiple destination

Consolidation
Plant A
Plant B
Plant C
Consolidation
Warehouse
X Y Z
Break-Bulk
Customer X
Customer Y
Customer Z
Break-Bulk
Warehouse
Plant A
Assortment
Reconfigure freight as it flows from origin to destination






Cross Docking Mixing Assembly
Cross-Dock
Plant A
Plant B
Plant C
Distribution
Warehouse
Customer Y
Customer Z
Customer X
Combine inventory from multiple origins into an assortment
for specific customer
Mixing
Plant A
Plant B
Plant C
Transit Mixing
Point
A B C
Product D
D
A
A
A B
B
B C
C
D
Customer W
Customer Y
Customer X
Customer Z
Assembly
Vendor A
Vendor B
Vendor C
Lead Supplier
Warehouse
Assy. Plant
Procure inventory from multiple Vendor to
support manufacturing operations
Postponement
Warehouse postpone commitment to final
product configuration by completing
final packaging, labeling, and light
manufacturing



Reduced Risk Lower Inventory
10
Stockpiling

Accommodate seasonal production or demand


Buffer Stock
11
Reverse Logistics
Perform physical work related to product
recall, reclamation, disposal of
overstock and damage inventory



Control Regular
12



Service
Establishing warehouse to service a specific
market area


- Spot Stocking
- Full Line Stocking
- Product Support
- Market Presence

13
Spot Stocking
Spot Stocked in a Local Market Warehouse in
Anticipation of Responding to Customer Need
During the Critical Sales Period Rather Than
Maintaining Inventory in a Warehouse Year-
round

Use temporarily Warehouse for Time Limited
Period
14
Full Line Stocking
Warehouse can provide one-stop
shopping capability for goods from
multiple manufacturers

Use Permanent Warehouse for
Unlimited Time Period
15
Production Support
Stock Inventory to Support Manufacturing
Operation

Support Warehouse Containing an Inventory of
Processed Materials, Components and
Subassembly
16
Market Presence

Respond faster to customer needs

Increase Market Share and Profitability
17
Warehouse Operation
The objective is to efficiently receive
inventory, possible store it until required
by the market, assembly it into complete
orders, and initiate movement to
customer


Handling Storage
Receiving - Active
In Storage Handling - Extended
Shipping
18
Warehouse Ownership




Private Public Contract
19
Warehouse Size

Min = SSL + Q

Max = SSL+T + Q
20
Flow of Goods in Warehouse


Receiving
Holding
Picking
Shipping
Flow of Goods in Warehouse

Receiving Receiving Receiving

Holding Holding Holding

Picking Picking Picking



Batch Forming
Packaging
Shipping
Storage Media
Physical Characteristics of Goods in
Stock
Solid Goods: Stack, Rack, Drawers
Number of items of each product in a
customer order
Storage Plan
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Low Volume Low Volume
Receiving Dock
Shipping Dock
High Volume
Storage/Retrieval Transport
1. Picker to Product System
A team of human order pickers, traveling to
storage location
2. Product to Picker System
An automated device, delivering items to
stationary order pickers
AS/RS

Block Stacking System
Item Retrieval by Trolley
x
y
A/R Machine
S
i
d
e

a
i
s
l
e
Central aisle
Item Storage and Retrieval By AS/RS
and Belt Conveyor
S
i
d
e

a
i
s
l
e
Location and Site
Criteria




Services Operating Cost
Faktor Lokasi
1. Pasar Dan Bahan Baku

Jasa Semen

Fragile Kertas

Berat Agro Industri


SERVICES COST
Faktor Lokasi

2. Tangible
. Transportasi . Utilitas
. Tenaga Kerja . Biaya Konstruksi
. Energi . Pajak
. Tanah . Bahan Penolong
. Insentif . Dll
Faktor Lokasi
3. Intangible
Iklim
Peraturan
Stabilitas Politik
Kemudahan Ekspansi
Budaya
Polusi
Dll
Tahapan Pemilihan Lokasi
Regional

Makro

Community

Mikro

Site
Metoda Pemilihan
Gravitasi
BEP
Transportasi
Point Rating
Simulasi
Metoda Gravitasi
Minimasi Ongkos Transportasi
Faktor Faktor Lain Tetap
(Sama Untuk Semua Pilihan Lokasi)
Menggunakan Koordinat Cartesian
Sebagai Basis
Formula Metoda Gravitasi

J = Ti Bi Ji / Ti Bi
Dimana:
Ti : Biaya Transport Dari Tiap Titik i Ke Lokasi
(Rp/satuan /Km)
Bi : Berat Yang Diangkut Dari / Ke Lokasi i
Ji : Koordinat Dari Titik i
Contoh Metoda Gravitasi
Data pasar
A : 10 ton; 5000/ton/km
B : 2 ton; 8000/ton/km
C : 8 ton ; 4000/ton/km
Koordinat:
A (13, 22) ; B (95,84) ; C (118,41)
Contoh Metoda Gravitasi
Jx = (5x10x13) + ( 8x2x95) + ( 4x8x118)
(5x10) + ( 8x2) + ( 4x8)
= 91,3 KM

JY = (5x10x22) + ( 8x2x84) + ( 4x8x41)
(5x10) + ( 8x2) + ( 4x8)
= 38,3 KM

Metoda BEP
A
B
Faktor Yang Lain Tetap ( Sama )
Fix Cost Dan Variable Cost Berbeda
Metoda BEP
Total Cost Lokasi A = Total Cost Lokasi B

FA + Q. VA = FB + Q.VB


Q = (FA - FB )/ (VB - VA )
Metoda Transportasi

Multi Lokasi
Faktor Lain Sama Kecuali Ongkos
Transport
Metoda Point Rating
Menggabungkan Faktor Tangible &
Faktor Intangible
Menggunakan Pendekatan Kwalitatif
Dan Kwantitatif
Prosedur
Identifikasikan Faktor Yang Relevan
Tentukan Bobot Setiap Faktor
Tentukan Rating Faktor Pada Setiap Lokasi
Hitung Bobot Score Pada Setiap Lokasi
Untuk Setiap Faktor
Jumlahkan Bobot Skor Pada Setiap Lokasi
Pilih Lokasi Yang Memiliki Skor Tertinggi
Contoh
Warehouse Design

Criteria





Services Cost
Warehouse Cost
Receiving Cost
Holding Inventory Cost
Retrieving Cost
Assembling to customer order Cost
Shipping Cost
Factors To Be Considered

Physical characteristics of products
Number of items in stock
Rate of storage and retrieval request

Warehouse Design
1. Determining the capacity: length, width and
height
2. Locating and sizing: receiving, shipping and
storage zones (including number of I/O port,
number, length and width of the aisles of
storage zone and the orientation of
stack/racks/drawers)
3. Selecting the storage medium
4. Selecting the storage/retrieval transport
mechanism
Basic Warehouse Design
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Receiving Area
Order Picking Area
Packaging or Unitizing Area
Staging Area
Bulk Storage
Area
Rack Storage
Area
Selecting The Storage/Retrieval
Physical Characteristics of goods
Packaging at the arrival
Composition of out going lots



Stack Rack Drawers

Sizing Receiving &Shipping

The Number of Truck Dock

ND = [dt/QT]

ND : Number of Dock Truck
d : Daily demand from all order
t : Average time required to load/unload a truck
Q : Truck Capacity
T : Daily time available to load/unload a truck
Example
Average daily demand is 27.000 units, outgoing
shipment are performed by trucks, with capacity
equal to 850 units. Average time to load a truck is
280 minutes and 15 working hours are available
every day


Number of dock truck:
ND = [d.t/Q.T]
ND = [27.000x280/850x(15x60)]
ND = 10

Storage Policy
1. Dedicated Storage policy:
Product is assigned at pre-established set position
Easy to implement but causes an under utilization
2. Random Storage policy:
Product allocation is decided dynamically on the basis of:
Current warehouse occupation
Future arrival and request-forecast
Allow a higher utilization of space but requires:
Each item be automatically identified
Update database of current position of all items
Storage Policy
3. Class Based Storage policy:
Product are divided into a number of
categories according to their demand
Each category is associated with asset of
zones where the goods are stored according
to random storage policy

Sizing of Storage Area
Dedicated Storage policy:


MD = max Ij(t)


MD : Number of required storage location
Ij(t) : Inventory level of item j at time t
n : Number of item

Random Storage policy:
Mr = max Ij(t) MD
n
j=1
Example of Storage Area
Product Lot Safety Stock
A 500 100
B 200 80

Dedicated Storage policy:
MD = max Ij(t)
= 600 +280 = 880

Random Storage policy:
Mr = max Ij(t) MD
= 600 + 180 = 780
Length and Width of Storage

Length: Lx = ( ax + wx )nx
Width : Ly = ( ay ny + wy )
Dimana:
ax : Occupation of a unit load along the direction of x
ay : Occupation of a unit load along the direction of y
wx: Width of side aisle along the direction of x
wy: Width of side aisle along the direction of y
nx: number of storage location along the direction of x
ny: number of storage location along the direction of y
A Traditional Storage Zone
L
x
L
y
Wy
Wx
Model of Sizing The Storage Zone
Minimize:



Subject to:
v
w n
v
n
w
y y y
x
x x
2 2
1
+
+
|
.
|

\
|
+
o
o
integer 0, n n
m n n n
y x
z y x
>
>
Determining nx and ny
Number of Storage Location Along Y Direction



Number of Storage Location Along X Direction

( )
z y
x x
y
n
w m
' n
o
+ o
=
2
1
2
( )
x x z
y
x
w n
m
' n
2
1
2 + o
o
=
| | | |
y y x x
' n n ' n n = = and
Example
Berapa ukuran luas gudang untuk menampung produk A
dan B diatas jika:
1. Jika setiap pallet produk A dan B memiliki dimensi yang
sama dan memerlukan 1.05x1.05 m2 area.
2. Barang akan diletakkan diatas rak dimana setiap raknya
terdiri atas 4 tingkat.
3. Lebar gang utama adalah 4 m dan gang lainnya 3,5 m
4. Cara penempatan barang dengan menggunakan random
policy
Example
( )
( )
25 . 32
4 05 . 1
05 . 1 780 2
'
05 . 6
05 . 1 4 2
05 . 1 780
'
2
5 . 3
2
5 . 3
=

+
=
=
+

=
y n
x n
Example
nx = 6 and ny = 33

Length: Lx = ( ax + wx )nx
= ( 1.05 +(3.5/2))x6
= 16.8 m
Width : Ly = ( ay nx + wy )
= (1.05x33+4)
= 39.65 m

Case
Suatu sistem logistik terdiri atas satu unit produksi,
satu depot dan 10 agen. Unit produksi berkapasitas
100.000 unit per tahun, ongkos set up sebesar
Rp.25.000.000/set up dan ongkos simpan pada
eselon produksi sebesar Rp. 20.000/unit/tahun,
waktu pengiriman barang dari unit produksi ke
depot 1 bulan sedangkan dari depot ke rertailer
ditunjukkan pada tabel berikut. Ongkos
pemesanan dari depot ke unit produksi sebesar Rp
1000.000/pesan, dan ongkos transport dari unit
produksi ke depot sebesar Rp. 50.000/unit,
sedangkan ongkos simpan pada eselon depot
sebesar Rp.40.000/unit/tahun. Adapun data pada
agen ditunjukkan pada tabel berikut
Data Pada Agen

Agen A
j
H
j
B
j
D
j
S
j
L
dj
C
dj

j Rp/Psn Rp/unit/thn Rp/unit unit/thn unit/thn thn Rp/unit
1 50000 4000 50000 5000 500 0.05 9500
2 40000 6000 50000 4000 400 0.03 8000
3 30000 8000 35000 4500 500 0.10 9000
4 60000 10000 40000 5000 500 0.10 8000
5 75000 12000 40000 6000 600 0.05 6000
6 65000 8000 30000 5500 550 0.05 6000
7 70000 10000 40000 6000 600 0.10 9000
8 60000 8000 45000 5000 500 0.05 6000
9 55000 12000 50000 4000 400 0.05 6000
10 70000 8000 40000 5000 500 0.03 5000
Berapa ukuran luas gudang di unit produksi, depot dan
setiap agen:
1. Jika setiap pallet produk memiliki dimensi yang sama dan
memerlukan 1.2x1.2 m2 area.
2. Barang akan diletakkan diatas rak dimana setiap raknya
terdiri atas 3 tingkat.
3. Lebar gang utama adalah 4 m dan gang lainnya 3,5 m
4. Cara penempatan barang dengan menggunakan random
policy