1. Background of Data Analysis
3-4. Relationship with Layout Diagrams
A Layout Diagram (Floor Plan) is a 2D/3D engineering drawing that optimally places various storage equipment (racks, automated warehouses, etc.), operational areas (inspection, packing, sorting, etc.), transport material handling equipment (conveyors, sorters, etc.), operational aisles, and buffer spaces within a distribution center's architectural space (building, pillars, walls, docks)
If layouts are drawn relying solely on intuition or experience, fatal problems arise—such as "insufficient storage racks," "operational areas being too narrow causing bottlenecks," or "forklift aisles intersecting causing traffic collision accidents" To create an excellent layout diagram, quantitative grounds based on data analysis (EIQ analysis) are indispensable
2) Engineering Process Details from EIQ Analysis to Layout Diagram Creation
In Tera Calculation, rather than drawing blueprints abruptly from numerical data, layout diagrams are derived through an extremely logical, step-by-step procedure: 【EIQ Analysis】 ──＞ 【EIQ Matrix Table Generation】 ──＞ 【Logistics Equipment Allocation】 ──＞ 【Integration into Logistics Flow Diagrams】 ──＞ 【Layout Diagram Completion】
Step 1: EIQ Analysis & "25-Block EIQ Matrix Table" Generation
Generate a "25-block EIQ matrix table" intersecting 5 item ranks × 5 destination ranks for target day shipping data Separate whole-case "Case Shipping" from fractional "Piece Shipping," clarifying cargo volume concentration from high-flow to low-flow zones
Step 2: Allocating "Logistics Equipment (Material Handling)" to the EIQ Matrix Table
Systematically allocate optimal storage and operational equipment based on item rank characteristics across the 25 blocks For example, assign automated warehouses (PL_AS/RS) or case sorters to high-moving A1 ranks, pallet racks or flow racks to medium-moving B ranks, and medium/light-duty shelving to low-moving D ranks Through this, storage capacities (pallet counts, shelf tier counts) and throughput volumes (cases/hour, pick lines/hour) that each piece of equipment must hold are directly calculated
Step 3: Integration into Quantitative "Logistics Flow Diagrams (Material Flow)"
Structure material flow lines passing through each process (Inbound Dock ──＞ Storage Area ──＞ Replenishment Line ──＞ Picking Zone ──＞ Sorting/Packing ──＞ Outbound Dock) as a "logistics flow diagram attached with numerical data (pallet counts, case counts, line counts, volume m³)" Visualizing volume transfer balances between processes and throughput peaks across time axes clarifies zone placement relationships (adjacency) and flow lines within the building
Step 4: Required Area Calculation & "Layout Diagram (Floor Plan)" Completion
Calculate required floor areas (m², sq ft) per zone by adding equipment pitch, machine units, operational aisle widths (forklift aisles 3.0–3.5m, worker aisles 1.2–1.5m, etc.), and operational area/buffer space margin ratios to "equipment throughput and storage volumes" established in the logistics flow diagram Fitting these area numbers into the building grid (column spans) completes the final floor plan layout diagram on CAD
3) "Comparative Evaluation of 3–4 Plans" & Pursuing Return on Investment (ROI) via Equipment Comparison and Layout Changes
In logistics system design, **persisting with a single layout plan from the outset is extremely dangerous** By creating **3–4 multiple comparison plans** with altered equipment selections or flow layouts and conducting simulations, the optimal plan (best practice) offering the best Return on Investment (ROI) can be extracted
【Why is Multiple Comparison of 3–4 Plans Necessary?】
- Plan A (Manual / Conventional Rack Focus / Capital Expenditure Suppression Type): Capital expenditure (CAPEX) is suppressed to a minimum, but it visualizes risks where future labor costs (OPEX) and operational error costs remain high
- Plan B (Standard Automation / Investment-Labor Cost Balance Type): Flow racks and DPS (Digital Picking Systems) are introduced for high-moving items only, while medium/low-moving items are operated via manual racks—a standard plan with an excellent ROI balance
- Plan C (Advanced Automation & Labor Saving / Future Investment Type): Automated pallet warehouses (PL_AS/RS), AGVs/AMRs (Autonomous Mobile Robots), and case sorters are fully deployed Although initial investment is large, labor cost reduction effects and processing speeds are maximized
- Plan D (Building Flow Alteration / Footprint Optimization Type): Dock locations or conveyor loop lines are altered, emphasizing flow line shortening that maximizes building structures (column spans and ceiling heights)
【Extracting the Optimal Plan via Return on Investment (ROI / Payback Period)】
Based on equipment capacity and required headcount calculated for each plan in Tera Calculation, initial investment amounts and running costs are quantitatively compared
Rather than merely "introducing state-of-the-art automated equipment," proving through numerical data **"whether the payback period falls within 5–7 years" and "whether future scalability accompanying business growth exists"** enables presenting proposals with unwavering persuasiveness to executive management and client shippers
