1. Background of Data Analysis
3-2. Relationship with Logistics Flow Diagrams
A Logistics Flow Diagram (Material Flow Diagram) is a master process chart that schematizes and structures physical product movements inside a distribution center—spanning a series of processes from inbound receipt to inspection, put-away, storage, picking, sorting, packing, outbound staging, and loading.
Going beyond a simple process flow indicating work steps, by mapping out material flow lines specifying "which process moves to which process, under what packaging/transport forms, and in what volume," it serves to detect warehouse bottlenecks early, minimize travel lines between zones, and optimize layout design.
2) Practical Procedures to Create Quantitative Logistics Flow Diagrams from EIQ Analysis
To create a "Quantitative Logistics Flow Diagram with Cargo Volume Figures" capable of withstanding engineering design rather than remaining a mere conceptual diagram (qualitative flow diagram), Tera Calculation applies the following logic.
Step 1: Creating an "EIQ Matrix Table" via EIQ Analysis
Execute EIQ analysis against shipping data for the target day (design benchmark day) reflecting future vision figures. Create a "25-block matrix table" intersecting item ranks (5 classifications) and destination ranks (5 classifications) to visualize volume distributions for case shipping and piece shipping respectively.
Step 2: Allocating "Logistics Equipment (Material Handling)" to the EIQ Matrix Table
In accordance with item rank characteristics (flowability/shipping frequency) categorized across the 25 blocks, allocate optimal storage and operational equipment to each block.
- High-Flow Zones (A1 & A2 Ranks): Allocate automated warehouses (PL_AS/RS), case AS/RS, mobile racks, flow racks, automated sorters, etc.
- Medium/Low-Flow Zones (B, C, & D Ranks): Allocate pallet racks, medium/light-duty fixed shelving, carousels, etc.
Step 3: Automated Calculation of "Throughput" across Each Process
Based on allocated logistics equipment, automatically aggregate volume passing through each process line from inbound to outbound (Inbound Dock → Storage Area → Replenishment Line → Picking Zone → Sorting Area → Outbound Dock). Volume is calculated not merely as "piece counts," but as effective operational units required for design (case counts, pallet counts, picking retrieval counts, volume m³, weight kg).
Step 4: Completion of Quantitative Logistics Flow Diagram (Material Flow) Based on Data
Complete the logistics flow diagram by attaching calculated throughput values to each arrow and line across processes. Through this, "how many pallets are transported from which equipment to the next sorting area" and "how many work lines are generated from picking racks" are quantitatively visualized, serving as direct calculation grounds for required processing capacities, equipment quantities, and areas.
