8. Warehousing Unmul

Warehousing Muriani Emelda Isharyani

Warehousing


Warehousing Muriani Emelda IsharyaniFunctionStorage in Transit Inventory

Economic ServiceConsolidation & Break Bulk - Spot Stocking Assortment - Full Line StockingPostponement - Product SupportStockpiling - Market PresenceReverse Logistics


Warehousing Muriani Emelda IsharyaniConsolidationPlant APlant BPlant CConsolidationWarehouseXYZ


Warehousing Muriani Emelda IsharyaniConsolidation


Warehousing Muriani Emelda IsharyaniConsolidation & Break BulkReduce Transportation Cost by using warehouse capability to increase shipment economic of scaleConsolidation, warehouse receives materials from number of sources which combined into a large single shipment to a specific destinationBreak-Bulk, operator receives a single large shipment and arrange for delivery to multiple destination


Warehousing Muriani Emelda IsharyaniBreak-BulkCustomer XCustomer YCustomer ZBreak-BulkWarehousePlant A


Warehousing Muriani Emelda IsharyaniBreak-Bulk


Warehousing Muriani Emelda IsharyaniAssortmentReconfigure freight as it flows from origin to destination

Cross Docking Mixing Assembly


Warehousing Muriani Emelda IsharyaniCross-DockPlant APlant BPlant CDistributionWarehouseCustomer YCustomer ZCustomer XCombine inventory from multiple origins into an assortment for specific customer


Warehousing Muriani Emelda IsharyaniCross-DockEnables receipt of full shipments from a number of suppliers, generally manufacturers, & direct distribution to different customers without storage


Warehousing Muriani Emelda IsharyaniMixingPlant APlant BPlant CTransit MixingPointABCProduct DDAAABBBCCDCustomer WCustomer YCustomer XCustomer Z


Warehousing Muriani Emelda IsharyaniAssemblyVendor AVendor BVendor CLead SupplierWarehouseAssy. Plant Procure inventory from multiple Vendor to support manufacturing operations


Warehousing Muriani Emelda IsharyaniPostponementAccommodate seasonal production or demandFor example, lawn furniture and toys are typically produced year-round but are sold only during a very short marketing period


Warehousing Muriani Emelda IsharyaniStockpilingTo accommodate seasonal production or demandFor example, agricultural products are harvested at specific times, with subsequent consumption occuring throughout the year


Reverse Logistics ProcessingFacilitate the reverse flow of product that did not sell or to accommodate recallsFacilitate the reverse flow of product following its useful life then update for sale at a discounted priceUse coordination & reverse flow to position & resell product when the original user no longer needs itReturns product following its useful life with the objective of decomposing it to its component materials so that they can be effectively reusedWhen material cant be effectively reused, it may dispose of it in the appropriate landfill


Service BenefitsMay increase cost but should also increase market sales, revenue and potentially gross marginWarehouses can provide service as a result of:Warehousing Muriani Emelda IsharyaniSpot-Stocking: stocking of products in strategically located warehouses during demand sensitive periodEx: agricultural implements are spot stocked during the growing season Full line stocking: stocking product inventory combinations from different manufacturers to provide one-stop shopping capability for customer. This will improve service by reducing the number of suppliers that a customer must logistically deal withValue-added services: any work that creates a greater value for customers. Ex: vegetables can be processed and canned in brights at the processing plants. Once a specific customer order is received, the warehouse can complete labeling and finalize packaging.


Warehousing Muriani Emelda IsharyaniFlow of Goods in Warehouse

ReceivingHoldingPickingShipping


Warehousing Muriani Emelda IsharyaniFlow of Goods in Warehouse

Receiving Receiving Receiving

Holding Holding Holding

Picking Picking Picking

Batch FormingPackagingShipping


Keuntungan Memaksimalkan penggunaan peralatanmemaksimalkan penggunaan personalefisiensi ruanganpengurangan biaya fasilitasKendala jika pengaturan aliran material tidak tertib dapat menimbulakan kesemerawutan dan kemacetan.Warehousing Muriani Emelda IsharyaniSentralisasi fungsi penerimaan dan pengiriman


Menerima seluruh material yang datang dari pemasok eksternal maupun internalmemeriksa material/barang yang datangmemeriksa dokumen yang menyertai material tersebutmencatat faktur penerimaanmencatat jika ada kunatitas/kualitas yang barang yang tidak sesuaimembuat laporan penerimaan barangmengirim ke tempat penyimpananWarehousing Muriani Emelda IsharyaniFungsi Penerimaan (Receiving)


Area alat angkutdockdoordockboardarea pallet atau containerarea penempatan produkkantoraisle

Warehousing Muriani Emelda IsharyaniFungsi Departemen Penerimaan


Melakukan pengepakan barang yang akan dikirimpemberian alamat pada karton pembungkus atau kontainermelakukan penimbangan kontainermelakukan penempatan trailerloading dan distribusi Warehousing Muriani Emelda IsharyaniFungsi Pengiriman (Shipping)


Jenis gudangbahan baku/suku cadang/ WIPbarang jadibarang untuk keperluan administrasiperalatanWarehousing Muriani Emelda IsharyaniPenyimpanan (Storage)


Warehousing Muriani Emelda IsharyaniStorage MediaPhysical Characteristics of Goods in StockSolid Goods: Stack, Rack, DrawersNumber of items of each product in a customer order


Warehousing Muriani Emelda IsharyaniSelecting The Storage/RetrievalPhysical Characteristics of goodsPackaging at the arrivalComposition of out going lots

Stack Rack Drawers


Warehousing Muriani Emelda IsharyaniWarehouse DecisionsPemilihan LokasiDesainProduct-Mix AnalysisExpansionMaterial HandlingLayoutSizing


Warehousing Muriani Emelda IsharyaniLocation and SiteCriteria

Services Operating Cost


Warehousing Muriani Emelda IsharyaniFaktor Lokasi1. Pasar Dan Bahan Baku

Jasa Semen Fragile Kertas

Berat Agro Industri

SERVICES COST


Warehousing Muriani Emelda IsharyaniFaktor Lokasi

2. Tangible . Transportasi . Utilitas. Tenaga Kerja . Biaya Konstruksi. Energi . Pajak. Tanah . Bahan Penolong. Insentif . Dll


Warehousing Muriani Emelda IsharyaniFaktor Lokasi3. Intangible IklimPeraturanStabilitas PolitikKemudahan EkspansiBudayaPolusiDll


Warehousing Muriani Emelda IsharyaniTahapan Pemilihan LokasiRegional

MakroCommunity

MikroSite


Warehousing Muriani Emelda IsharyaniMetoda PemilihanGravitasiBEPTransportasiPoint RatingSimulasi


Warehousing Muriani Emelda IsharyaniMetoda GravitasiMinimasi Ongkos TransportasiFaktor Faktor Lain Tetap ( Sama Untuk Semua Pilihan Lokasi)Menggunakan Koordinat Cartesian Sebagai Basis


Warehousing Muriani Emelda IsharyaniFormula 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 iJi : Koordinat Dari Titik i


Warehousing Muriani Emelda IsharyaniContoh Metoda GravitasiData pasarA : 10 ton; 5000/ton/kmB : 2 ton; 8000/ton/kmC : 8 ton ; 4000/ton/km Koordinat: A ( 13, 22) ; B (95,84) ; C(118,41)


Warehousing Muriani Emelda IsharyaniContoh Metoda GravitasiJx = (5x10x13) + ( 8x2x95) + ( 4x8x118) (5x10) + ( 8x2) + ( 4x8) = 91,3 KM

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


Warehousing Muriani Emelda IsharyaniMetoda BEPABFaktor Yang Lain Tetap ( Sama )Fix Cost Dan Variable Cost Berbeda


Warehousing Muriani Emelda IsharyaniMetoda BEP Total Cost Lokasi A = Total Cost Lokasi B

FA + Q. VA = FB + Q.VB

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


Warehousing Muriani Emelda IsharyaniMetoda Transportasi

Multi LokasiFaktor Lain Sama Kecuali Ongkos Transport


Warehousing Muriani Emelda IsharyaniMetoda Point RatingMenggabungkan Faktor Tangible Dan Faktor IntangibleMenggunakan Pendekatan Kwalitatif Dan Kwantitatif


Warehousing Muriani Emelda IsharyaniProsedurIdentifikasikan Faktor Yang RelevanTentukan Bobot Setiap FaktorTentukan Rating Faktor Pada Setiap LokasiHtung Bobot Score Pada Setiap Lokasi Untuk Setiap FaktorJumlahkan Bobot Skor Pada Setiap LokasiPilih Lokasi Yang Memiliki Skor Tertinggi


Warehousing Muriani Emelda IsharyaniContoh Banten Bandung Surabaya Faktor Bobot Rat. Bobot Rat. Bobot Rat. Bobot Skor Skor Skor Skor Skor Skor

O.Ops 0.33 50 16.5 40 13.2 35 11.35 B.Baku 0.25 70 17.5 80 20.0 75 18.75 T.Kerja 0.20 55 11.0 70 14.0 60 12.00 B.Hidup 0.05 80 4.0 70 3.5 40 2.00Lingkung. 0.02 60 1.2 60 1.2 60 1.20Pasar 0.15 80 12.0 90 13.5 85 12.75 1.00 62.60 65.40 55.25


Warehousing Muriani Emelda IsharyaniWarehouse Design Criteria

Services Cost


Warehousing Muriani Emelda IsharyaniWarehouse CostReceiving CostHolding Inventory CostRetrieving CostAssembling to customer order CostShipping Cost


Warehousing Muriani Emelda IsharyaniFactors To Be Determined

Number of floors to include in the facilityA cube utilization planProduct flow


Warehousing Muriani Emelda IsharyaniWarehouse DesignDetermining the capacity: length, width and heightLocating 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)Selecting the storage mediumSelecting the storage/retrieval transport mechanism


Warehousing Muriani Emelda Isharyani Sizing Receiving &ShippingThe Number of Truck Dock

ND = [dt/QT]ND : Number of Dock Truckd : Daily demand from all ordert : Average time required to load/unload a truckQ : Truck CapacityT : Daily time available to load/unload truck


Warehousing Muriani Emelda IsharyaniExampleAverage 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


Warehousing Muriani Emelda Isharyani Storage Policy1. Dedicated Storage policy:Product is assigned at pre-established set positionEasy to implement but causes an under utilization2. Random Storage policy:Product allocation is decided dynamically on the basis of:Current warehouse occupationFuture arrival and request-forecastAllow a higher utilization of space but requires:Each item be automatically identifiedUpdate database of current position of all items


Warehousing Muriani Emelda Isharyani Storage Policy3. 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


Warehousing Muriani Emelda IsharyaniSizing of Storage AreaDedicated Storage policy:

MD = max Ij(t)MD : Number of required storage locationIj(t) : Inventory level of item j at time tn : Number of item

Random Storage policy:Mr = max Ij(t) MD nj=1


Warehousing Muriani Emelda IsharyaniExample of Storage Area Product Lot Safety Stock P 500 100 Q 200 80Dedicated Storage policy: MD = max Ij(t) = 600 +280 = 880

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


Warehousing Muriani Emelda IsharyaniLength and Width of StorageLength: Lx = ( ax + wx )nxWidth : Ly = ( ay ny + wy )

dimana:ax : Occupation of a unit load along the direction of xay : Occupation of a unit load along the direction of ywx: Width of side aisle along the direction of xwy: Width of side aisle along the direction of ynx: number of storage location along the direction of xny: number of storage location along the direction of y


Warehousing Muriani Emelda IsharyaniA Traditional Storage ZoneWyWx


Warehousing Muriani Emelda IsharyaniModel of Sizing The Storage ZoneMinimize:

Subject to:


Warehousing Muriani Emelda IsharyaniDetermining nx and nyNumber of Storage Location Along Y Direction

Number of Storage Location Along X Direction


Warehousing Muriani Emelda IsharyaniExampleBerapa ukuran luas gudang untuk menampung produk P dan Q diatas jika:Jika setiap pallet produk P dan Q memiliki dimensi yang sama dan memerlukan 1.05x1.05 m2 area. Barang akan diletakkan diatas rak dimana setiap raknya terdiri atas 4 tingkat.Lebar gang utama adalah 4 m dan gang lainnya 3,5 mCara pemenpatan barang dengan menggunakan random policy


Warehousing Muriani Emelda IsharyaniExample


Warehousing Muriani Emelda IsharyaniExamplenx = 6 and ny = 33

Length: Lx = ( ax + wx )nx = ( 1.05 +(3.5/2))x6 = 16.8 m

Width : Ly = ( ay ny + wy ) = [(1.05x33)+4] = 38.65 m


Warehousing Muriani Emelda IsharyaniTugasSuatu 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


Warehousing Muriani Emelda IsharyaniData Pada Agen

Agen Aj Hj Bj Dj Sj Ldj Cdj 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 600010 70000 8000 40000 5000 500 0.03 5000


Warehousing Muriani Emelda IsharyaniBerapa ukuran luas gudang di unit produksi, depot dan setiap agen: Jika setiap pallet produk memiliki dimensi yang sama dan memerlukan 1.2x1.2 m2 area. Barang akan diletakkan diatas rak dimana setiap raknya terdiri atas 3 tingkat.Lebar gang utama adalah 4 m dan gang lainnya 3,5 mCara penempatan barang dengan menggunakan random policy


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8. Warehousing Unmul