advancedLogistics facility planningIn order to plan and build a next-generation distribution center with excellent return on investment (ROI), it is necessary to take a multifaceted approach that goes beyond simply aggregating numbers.Logistics data analysisis required.
Simply calculating the shipment quantity does not reveal the flow of work at the site, the transformation of packaging, or the bottlenecks in the flow line within the warehouse.Careful before data analysisCurrent status surveyBy doing this and verbalizing and quantifying the tacit knowledge in the field, we can create a stable and robust system.EIQ analysisIt is possible to select material handling equipment.
In this paper,Logistics facility planninglead to successLogistics data analysisFrom the thought process ofCurrent status surveyThe point ofEIQ analysisComprehensive explanation of practical procedures.
Logistics data analysisWhen embarking on this process, the first thing to understand is that the way in which physical quantities are perceived is completely different depending on the department within the company.If you proceed with data analysis without understanding this gap in perspective, the designedLogistics facility planningThis can cause a significant deviation from on-site operations.
Understand the quantity of goods in terms of "amount (yen)" such as sales and purchases.High unit price, compact products and cheap, huge products are treated equally in terms of price, but the space they occupy in the warehouse and the workload are completely different.
This is determined by "quantity" such as the number of units sold or the number of cases.However, it does not take into consideration cargo handling attributes such as when, in what packaging form (pallet, case, bulk), and to which delivery destination.
We understand the number of shipped cases, weight (kg/t), and volume (CBM/M3), and evaluate truck loading rates and warehouse storage efficiency.
highly effectiveLogistics facility planningIn order to formulate the"Understand the relationship between product attributes, shipping methods, packaging (PCB), and quantity in three dimensions along the 'passage of time (time axis)' such as 24-hour and annual waves."Must be.
Appropriate material handling equipment and movement lines cannot be designed with only "point" data such as a single total number of shipments.We will build a multidimensional data model that combines the "line (From-To)" that represents movement from the shipping source to the shipping destination, and the concepts of "time axis (waves by time zone)," "packing style (PCB)," and "work area area (m2)."This makes the basic systemEIQ analysisorEIQVT analysisThis allows for seamless expansion.
Distribution centers that handle sales logistics have severe operational characteristics that are different from production distribution warehouses.
Packaging patterns for each process of receiving, storage, and shippingP (Pallet)、C (Case)、B (Bara/Piece)There is a method for quantitative analysis by classifying into three units.PCB analysisis.Sites with a high ratio of "P input ➔ B output" require a vast piece picking area and a highly functional WMS, while sites with a high ratio of "C input ➔ C output" require automatic sorters.logistics systemThis will be the deciding factor in system selection, as it will be effective.
Logistics data analysisBy comparing the "peak demand processing capacity (cases/hour, piece/hour)" derived from the above with the standard processing capacity of the following material handling equipment, we calculate the appropriate number of material handling machines and lines.
| Standard logistics equipment/system name | Standard processing capacity guide (standard value) | Main applicable work/shipping zones |
|---|---|---|
| A type automatic Pic machine | 1,200 totes (Oricon) / hour | High-speed picking of small items and high-flow bulk items |
| SAS (case ordering system) | 600 cases/hour | Automatic buffering and sequential shipping of medium-flowing case products |
| High-speed piece/case sorting machine (sorter) | 2,000 ~ 10,000 cases (pieces) / hour | Secondary sorting and sorting by delivery destination after batch picking |
| High-speed branching and merging conveyor line | 2,000 to 6,000 cases/hour | Case merging/inspection line from multiple picking zones |
| Belt conveyor (conveying speed 20-70m/min) | 1,800 to 3,600 cases/hour | Sectional sorting/horizontal conveyance line for fixed length cases |
Logistics data analysisThe required processes before entering the warehouse are on-site at the distribution center.Current status surveyis.Physical constraints and human operation costs that cannot be understood using data (CSV, etc.) alone can beCurrent status surveyOrganize using votes.
We interview and measure the number of registered master items, the number of actual items stored at all times, the average and maximum number of cases in stock, the number of storage stages and storage efficiency for each pallet/case/bulk.
Identify shipping format (PL/case/bulk ratio), number of registered shipping destinations, average number of shipping destinations per day, number of trucks dispatched, time schedule, and monthly/annual volume fluctuation ratio.
We will investigate the method of receiving orders (EOS, Web, EDI, Tel, Fax), closing time (reception time), number of shipping instructions, presence or absence of WMS, all area/partial location management method, and inspection method (BCR/visual inspection).
Logistics data analysisThe biggest hurdle that everyone faces when doing this is ``missing or inputting errors in the provided data (core data/WMS data)''.Even for major manufacturers that tend to have particularly strict data management, there is a surprisingly high probability that product size (three-sided dimensions), volume (CBM), and weight are not entered or inconsistent in shipping data.There are structural reasons for this, including the following:
Input fields such as "product volume (M3)", "length/width/height dimensions" and "case weight" are already prepared in the core system or WMS (warehouse management system) at the design stage.However, if daily ordering and billing work is completed only in terms of "number of cases" or "number of pieces," these volume and dimension items are not needed in daily work.As a result, when registering the product master, values are left blank or dummy values (such as "0" or "1") are entered.
When a new product is introduced, the sales and product planning departments responsible for master registration pay close attention to the sales amount and number of cases, but logistics attribute data such as the outside dimensions of the case after packaging and the number of stacks loaded on pallets tend to be treated as low priority.If a feedback operation is not established in which the logistics department actually inspects and measures items and updates the master, data will be accumulated without maintenance.
Larger manufacturers have multiple manufacturing plants and outsourced 3PL warehouses across the country.If input rules are not unified for each location, such as whether to register individual dimensions or external case dimensions, and whether the units are millimeters (mm) or centimeters (cm), digit errors and unit confusion (writing errors) will occur frequently when company-wide data is combined.
Assuming that there are data omissions and writing errors specific to these manufacturers,Current status surveyand incorporate logic to appropriately correct and remedy data analysis transactions.
Logistics facility planninginLogistics data analysisTherefore, it is necessary to use different analytical methods depending on the purpose, or to combine them for multifaceted verification.
Work activity-based costing:This is a method that subdivides each work process in a warehouse (receiving, inspection, storage, picking, packing) into "Activities" and calculates the unit price (driver) from the labor and equipment costs for each task.
example:If a part-time worker with an hourly wage of 1,200 yen picks 300 cases per hour, the work cost per picked case is calculated as 4 yen/case.It is effective in identifying high-cost processes that are bottlenecks and converting improvement effects into monetary amounts.
Priority management method:This method sorts all SKUs in descending order of shipment quantity and sales amount, and categorizes them into A rank (top 20%), B rank (middle 30%), and C rank (bottom 50%) based on cumulative ratio.
Pareto's law:At many logistics sites,The top 20% of A-rank items account for 70% to 80% of the total quantity..This directly leads to flow line optimization, where A-rank products are placed close to shipping ports or on automated lines, and C-rank products (long-tailed, low-flow products) are placed on high-density shelves.
Systematized by logistics consultant Shin SuzukiEIQ analysisFrom the shipping transaction dataLogistics facility planningThe most powerful tool that can directly derive the functional requirements necessary forLogistics data analysisIt's a method.
By cross tabulating these three elements and visualizing them as matrices and distribution curves (EQ curves, IQ curves, EN curves, etc.), it is possible to determine whether "individual picking (single picking)" or "batch sowing picking (batch picking + secondary sorting) is appropriate."logistics systemThe framework can be determined objectively and logically.
Logistics facility planningto succeedEIQ analysisProceeds strictly in the following eight steps:
EIQ analysisAs a result, instead of entrusting all work to excessively automated equipment, it is possible to define a hybrid operation concept with high cost performance, such as ``automating material handling for high-flow A-rank products'' and ``low-tech operation using fixed shelves (manual work with work support) for low-flow C-rank products.''
actualLogistics facility planninginEIQ analysisWe use SQL databases and other tools to aggregate and analyze millions of shipping details.
Calculate the quantity ratio by temperature range such as room temperature, chilled, frozen, etc., or by shipper/category.For example, if frozen items account for more than 90% of the total, we will focus our investment on cold-resistant material handling equipment that can withstand ultra-low temperature environments and high-speed automatic picks that minimize the time spent in the freezer.
Create a shipping matrix that plots the shipping destination (E) on the vertical axis, the item (I) on the horizontal axis, and the shipped quantity (Q).We will divide the area into ``Large lot area,'' ``Small lot frequent area,'' and ``Ultra-low flow area,'' and clearly separate the scope of application of sorters and the scope of application of SAS (Sequential high-speed warehousing system).
Logistics data analysis・EIQ analysisThe ultimate goal is not to look at the analysis screen, but to translate it into an actual "distribution center floor layout diagram (drawing)."
Conclusion:certainCurrent status surveyand objectiveLogistics data analysis（EIQ analysis・PCB analysis) based onLogistics facility planningThis is the only way to ensure "improved work efficiency," "zero incorrect shipments," and "minimized total logistics costs" after operation.