AutoPalletP3 A Powerful Decision Support Tool for Pallet Picklist Planning Copyright © 2000

AutoPalletP3AutoPalletP3

A Powerful Decision Support Tool for

Pallet Picklist Planning

Copyright © 2000

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What Is AutoPalletP3?What Is AutoPalletP3?

• Case-picking expert system• Originally developed for exclusive use of

Procter & Gamble• Now available as a licensed software package• Runs on most operating systems: from PC to

mainframe• Designed and installed by Warehouse

Optimization LLC, a team of operations research experts

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What Can AutoPalletP3 Do for What Can AutoPalletP3 Do for Your Warehouse Operations?Your Warehouse Operations?

• Eliminates damage caused by improperly loaded pallets

• Reduces errors in picking orders to pallets for shipping to individual customers

• Reduces time for picking orders to pallets• Reduces training time and costs for

introducing new personnel• Cuts space requirements

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Eliminates Damage Caused by Eliminates Damage Caused by Improperly Loaded Pallets Improperly Loaded Pallets

Instead of building THIS… you can build THESE...

Result: less product damage in transit, easier unloading, better fit with customer needs

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Reduce Errors and Time in Reduce Errors and Time in Picking Orders to PalletsPicking Orders to Pallets

AutoPalletP3 takes THIS…..and turns it into THESE….

Result: faster picking and load building

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What Can AutoPalletP3 Do for What Can AutoPalletP3 Do for Your Warehouse Operations?Your Warehouse Operations?

• Increases overall productivity• Eliminates rework caused by need to re-pack

pallets that won’t fit vehicle efficiently• Reduces worker’s compensation claims by

allowing two pallets to be stacked rather than building on tower

• Customizes pallet load configuration for each customer

• Increases efficiency in loading vehicles correctly the first time with more cube

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Significantly Reduces Significantly Reduces Unsaleables & Lost SalesUnsaleables & Lost Sales

Unsaleables in grocery industry is a MAJOR issue

• Unsaleables: 0.96% sales = $4.0 Billion

• Unsaleables caused by poor pallet configuration and loading: 0.44% sales = $1.8 Billion

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Almost Eliminates Crush, Almost Eliminates Crush, Straddle, and Other Common Straddle, and Other Common ProblemsProblems

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Increases Productivity & Increases Productivity & Reduces Learning CurveReduces Learning Curve

• Pickers spend 10-15% of their time working out HOW to stack product

• Case study: P&G Health & Beauty Products Plant– AutoPalletP3 increased productivity 12% in first month

(20% in the first year)– Reduced picker learning curves by 75% – very

important in most operations, where picker turnover high

• Bottom line: very quick return on investment

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AutoPalletP3 Makes Picking and AutoPalletP3 Makes Picking and Pallet Building SaferPallet Building Safer

• Supports picking tall pallets in two pieces that can be fit together without damage

• Eliminates:– “Throwing” cases– Too-high lifts QuickTime™ and a

GIF decompressorare needed to see this picture.

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AutoPalletP3 “Cubes Out” LoadsAutoPalletP3 “Cubes Out” Loadsas Efficiently as Possibleas Efficiently as Possible

• Optimizes loading sequence and fit for specific vehicle:

• Adjusts pallet height to accommodate cube• Case study:

– Operation “cubes out” trailers before it “weights out”– Truck cube utilization increased 22%– Annual freight savings 22%

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How AutoPalletP3 WorksHow AutoPalletP3 Works

• AutoPalletP3 is an expert system• Plans orders by knowing everything about the

product, where the pick locations are, and how we want the loads to be built

• Works by following a list of RULES

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Picklists are generated based on RULES and then converted automatically into optimized loads.


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• Takes each complete order and converts it into picklists

• Uses more than 20 RULES to make decisions, and a scoring system to resolve conflicts among RULES

• May try up to 500 different solutions until it finds the best result for the TOTAL order - not just for one pallet

• Sample RULE: Keep products with strong odors away from those susceptible to damage from such odors

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Just a Few of AutoPalletP3’s Just a Few of AutoPalletP3’s RulesRules

Plan the orders as a series of DOUBLE SETS, which when paired up correctly will fit in the truck in the least number of pallet spaces.

The lower set MUST have a flat top, of a large enough area to rest the upper pallet on it without damage. There are height limits for each set.

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Wherever possible, build in layers of even height, by combining products which have the same height cases.

Use full product layers when available, and if more than one layers is needed of an SKU, start the pallet with that, which might give the picker the chance to use an existing part-load.

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If an order asks for a quantity which is more than one layer, but not an exact layer quantity, keep it all on one pallet if possible. But if you cannot - because the lowerset must have a flat top - then the odd cases MUST be on the same DOUBLE SET.

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Minimize layeroverhang. Undersize layers need to go ON TOP OF larger layers, not below them or product may be damaged.OK

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When making up a layer from mixed cases, there is a minimum“coverage factor”.

This would NOT be a goodlayer.

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Minimize straddles - this is when a case restson two cases of different heights.

It may be better with odds at the top of anupper set to stack them on top of each other.

OK

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Do not make a mixed-case layer too large either - it must not overhang the pallet.

However, a full layer of one sku MAY overhang the pallet if this is its normalpattern.OK

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Just a few of AutoPalletP3’s Just a few of AutoPalletP3’s rulesrules

And there are strict rules tominimize travel distance andrepeat visits to the same location - but these have to be traded offagainst the other rules.

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• PC AutoPalletP3

• Integrated AutoPalletP3 (embedded in your Warehouse Management System)

ORDERDOWNLOADPC AUTOPALLETPicklist

WMSAUTOPALLETOR


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The importance of RULES can be adjusted for any location.

ImportanceMinimizeoverhang

RulesMinimizenon-

contiguousUPC’s

Strongestcases on

bottom

Minimizetravel

distance

Keep strongodors away

fromsusceptible

product

Maximize #of layers

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AutoPalletP3 DataAutoPalletP3 Data

• Item master– Case weight and dimensions– Layer dimensions– Cases per layer

• Order data– Pallet type and size– Product required and location

• Warehouse data• Layout

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PaybackPayback

• Case study - When P&G implemented AutoPalletP3 at two sites in the US, they quickly realized savings

• Payback in 19 days (yes, 19 days)• More importantly, P&G’s customers benefited

significantly from much more accurate and damage-free shipments

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AutoPalletP3 HistoryAutoPalletP3 History

• Developed in 1992• Enhanced in 1993, 1994, 1995, 1996, 1998• Operating on 3 continents• Run on millions of cases weekly• Originally proprietary to P&G – now available

to other companies• Supported by Warehouse Optimization, LLC

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AutoPalletP3 Installation & AutoPalletP3 Installation & SupportSupport

• AutoPalletP3 is performance-tuned for each installation

• Our team of experts:– Gathers information about your installations– Reviews your needs– Creates interfaces with existing systems– Installs the new system– Trains your people– Is available for ongoing support

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Who Is Warehouse Optimization Who Is Warehouse Optimization LLC?LLC?

• Warehouse Optimization, LLC is an international partnership–an offshoot of Moore & Associates

• Dedicated to using technology to enhance warehouse operations

• Experienced in using operations research techniques to create expert systems by learning from the people who actually do the job

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Contact Us for More Information Contact Us for More Information and to Arrange a Test Driveand to Arrange a Test Drive

• Please visit our web site at: www.AutoPalletP3.com

• Contact us to arrange a free, no-obligation discussion and on-site demonstration of how AutoPalletP3 can benefit your operations.

• Warehouse Optimization, LLCPhone (615) 791-8000Email: [email protected]

Documents

AutoPalletP3 A Powerful Decision Support Tool for Pallet Picklist Planning Copyright © 2000