DEPARTEMENT BEDRYFS- EN SISTEEMINGENIEURSWESE DEPARTMENT OF INDUSTRIAL AND SYSTEMS ENGINEERING
COVER PAGE FOR FINAL PROJECT DOCUMENT(BPJ 420) - 2012
Information with regards to the mini-dissertation Project Title: (e.g. A Contingency framework for the after-sales inventory at Nissans Part Distribution Centre)
Facility Plan for Unilever
Author (Last name, Initials) Mbatha W.P Student number 26481121 Supervisor/s (Last name, Initials) Kruger P.S Date (month/day/year) September-05-2012 Keywords (Provide keywords from your project (for searching purposes). The first word of two words must always have a capital first letter and the rest of the words following must be lower case. In the event of an abbreviation, use as it is known. E.g. Economic recession, ABSA, ERP, Simulation modelling)
Unilever Facilities Plan, Project Waterfall
Abstract (Provide an abstract of the mini-dissertation. An abstract is a short summary of the contents covered in the item.)
Using systems dynamics and facilities planning principles to overcome inventory planning and Flow design for a fast moving goods factory.
Category (Enter the category in which the project was done. E.g. Operations Research, Simulation, Logistics…)
Facilities Planning, Industrial Analysis
Declaration 1. I understand what plagiarism is and I am aware of the University's policy in this regard. 2. I declare that this is my own original work 3. Where other people's work has been used (either from a printed source, internet or any other source) this has been carefully acknowledged and referenced in accordance with departmental requirements 4. I have not used another student's past work to hand in as my own 5. I have not allowed and will not allow, anyone to copy my work with the intention of handing it in as his/her own work Handtekening Signature
A Facility and Work Flow design for Unilever
by
Wiseman P. Mbatha 26481121
Submittedinpartialfulfilmentoftherequirementsfor thedegreeof
BACHELORSOFINDUSTRIALENGINEERING
inthe
FACULTYOFENGINEERING,BUILTENVIRONMENTANDINFORMATION TECHNOLOGY
UNIVERSITYOF PRETORIA
October 2012
Executive Summary
The main aim of this document is to serve as a design recommendation and a recorded documentation for the tactical decisions that had to be made when designing the factory. The report also serves as a design guide line for future projects that will be done by Unilever. The document was created by a student from the University of Pretoria as part of his final year project.
An appendix with the designs and simulation models will be attached at the end of the document. When developing the designs the student had to do research on best practices available in the industry this was done by consulting companies, going on reliable internet sources recommended by the departments’ library and reading articles relating to the subject.
The major challenge that was faced throughout the project is that decisions are made as the project progresses but using industrial and systems engineering a reliable team of people the project progressed without major design problems. The key to the success of the project is that the company keeps record of most of their work which makes it easier to retrieve information when needed.
Table of Contents Executive Summary .................................................................................................................. i
Table of Figures ....................................................................................................................... v
1 Introduction ...................................................................................................................... 1
2 Project Description ........................................................................................................... 2
3 Expected Project Outcomes ............................................................................................ 3
First Outcome ...................................................................................................................... 3
4 Interim Report findings summary and review .................................................................. 4
4.1 Purchasing Extra piece of land ................................................................................. 4
4.2 Layout Options ......................................................................................................... 5
5 Literature Review ............................................................................................................. 6
General ................................................................................................................................ 6
Efficient operation ................................................................................................................ 7
Picking best practices .......................................................................................................... 7
5.1 Material handling equipment .................................................................................... 9
5.1.1 Material handling trends in 2012 ....................................................................... 9
5.2 Forklift power sources ............................................................................................ 11
5.2.1 Electric forklift considerations .......................................................................... 11
5.2.2 Gas versus Electric Folklifts ............................................................................ 12
5.2.3 Hydrogen forklifts ............................................................................................ 13
5.3 Forklift types ........................................................................................................... 13
5.3.1 Hand operated forklifts .................................................................................... 13
5.3.2 High-level forklifts ............................................................................................ 14
5.3.3 Heavy duty forklifts .......................................................................................... 14
5.3.4 Narrow isle trucks ............................................................................................ 14
5.3.5 Forklift type comparison .................................................................................. 15
5.4 Automated storage ................................................................................................. 15
5.5 Storage equipment ................................................................................................. 16
5.5.1 Racking options ............................................................................................... 16
5.6 Conclusion on Literature Review ............................................................................ 16
5.7 Key inbound considerations ................................................................................... 17
5.8 Key outbound considerations ................................................................................. 17
6 Design Approach ........................................................................................................... 18
7 Inbound Material Flow ................................................................................................... 19
Inbound process flow ........................................................................................................ 24
8 Systems Dynamics Factory model ................................................................................ 28
8.1 Modelling approach ................................................................................................ 29
8.2 Analysis parameters of the model .......................................................................... 30
8.3 Inventory Calculations ............................................................................................ 31
8.3.1 Loading bay space requirement for white bottles ............................................ 31
8.3.2 Loading bay space requirement for Lavender Bottle inventory ....................... 32
8.3.3 Rack space requirement ................................................................................. 33
8.3.4 Packaging Cases Inventory ............................................................................. 34
8.3.5 Raw Material Inventory .................................................................................... 35
8.3.6 Total Number of Pallets in the warehouse ...................................................... 36
8.3.7 Analysis of the results ..................................................................................... 36
8.3.8 Empty pallets and waste management ........................................................... 37
8.3.9 Analysis of results ........................................................................................... 37
8.4 Warehouse layout options ...................................................................................... 38
8.4.1 Storage design considerations ........................................................................ 38
8.4.2 Requirements for receiving ............................................................................. 38
8.4.3 The block layout .............................................................................................. 38
8.4.4 The proposed warehouse layout ..................................................................... 39
8.4.5 Warehouse with loading bays ......................................................................... 40
8.5 Labelling the Racking System ................................................................................ 41
8.5.1 Raw material allocation ................................................................................... 44
9 Processing and Packaging of material .......................................................................... 46
9.1.1 Packaging Process description ....................................................................... 46
9.1.2 Handy Andy Making Process Description ....................................................... 48
9.1.3 Allocation of Packaging lines ........................................................................... 49
9.1.4 Pouch line 1 ..................................................................................................... 50
9.1.5 Sunlight Bottle line ........................................................................................... 51
9.1.6 Domestos and Omo ........................................................................................ 52
9.1.7 Handy Andy line .............................................................................................. 54
9.1.8 Fabric Softener ................................................................................................ 55
9.1.9 Challenge ........................................................................................................ 56
9.2 Product Rework Handling ....................................................................................... 58
9.3 Space and Ergonomic Requirements ..................................................................... 58
10 Outbound Material Flow ............................................................................................. 59
10.1 Finished Goods inventory Graph ............................................................................ 62
10.2 Finished Goods warehouse .................................................................................... 63
10.2.2 Available layout options ................................................................................... 63
10.3 Palletizing principles ............................................................................................... 64
11 Conclusion and Recommendations ........................................................................... 65
11.1 Final recommendations .......................................................................................... 65
12 References ................................................................................................................. 66
13 Appendix A ................................................................................................................. 67
13.1 Tree diagram .......................................................................................................... 67
13.2 Analytical Hearachy Process .................................................................................. 68
14 Appendix B ................................................................................................................. 71
15 Appendix B ................................................................................................................. 72
15.1 Inventory Model ...................................................................................................... 72
15.2 Appendix C ............................................................................................................. 76
16 Appendix D ................................................................................................................. 77
Table of Figures Figure 1: Unilever Boksburg ................................................................................................... 1 Figure 2: Boksburg Current Liquids factory ............................................................................ 2 Figure 3: Alternative layouts ................................................................................................... 5 Figure 4: Combined inbound flow analysis ........................................................................... 27 Figure 5: Systems Engineering Model .................................................................................. 28 Figure 6: Simulation approach .............................................................................................. 29 Figure 7: Causal relationship diagram .................................................................................. 30 Figure 8: Stock and flow diagram ......................................................................................... 30 Figure 9: White bottle inventory ............................................................................................ 31 Figure 10: Lavender Bottle inventory .................................................................................... 32 Figure 11: Wrapping Plastic and Caps inventory .................................................................. 33 Figure 12:Cases Inventory .................................................................................................... 34 Figure 13: Raw material inventory ........................................................................................ 35 Figure 14: Total raw material inventory ................................................................................. 35 Figure 15: Total material inventory ....................................................................................... 36 Figure 16:Empty Pallet inventory .......................................................................................... 37 Figure 17: Original Fishbone Warehouse Layout ................................................................. 39 Figure 18: Fishbone Warehouse Layout ............................................................................... 40 Figure 19: Material Allocation Criterions ............................................................................... 41 Figure 20: Packaging Process .............................................................................................. 47 Figure 21:Shelf allocation strategy ........................................................................................ 49 Figure 22: Handy Andy and Sunlight Pouches ..................................................................... 50 Figure 23: Sunlight Bottle ...................................................................................................... 51 Figure 24: Domestos and Omo Bleach Bottles ..................................................................... 52 Figure 25: Handy Andy ......................................................................................................... 54 Figure 26: Sunlight Fabric softener ....................................................................................... 55 Figure 27 .............................................................................................................................. 68 Figure 28 .............................................................................................................................. 68 Figure 29 .............................................................................................................................. 69 Figure 30 .............................................................................................................................. 69 Figure 31 .............................................................................................................................. 69 Figure 32 .............................................................................................................................. 70
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0 Final Projober 2012
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0 Final Projober 2012
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0 Final Projober 2012
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0 Final Projober 2012
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0 Final Projober 2012
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following pa
g: acking – cocomponent
king: Drive-Thro
Systems. Racking:
an inclined
king:
pporting raart runs on t has a plat
reased sele. Mobile
is designunity for hig
required foe is requireking.
eview n indicated
allet racking
onsumer gots and parts
ough Rac
d track with
ack, shuttle the rails a
tform on the
ectivity: racking ised to givegh capacity
or every twod per every
d in this d
g options as
oods; s and
cking
hin a
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s e y
o y
document a
P
s an examp
a number
age | 16
le of the
of key
BPJ 4210 Octo
5.7 KWarehoefficiencgoods sparticul
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0 Final Projober 2012
Key inbouousing bescy and accstored in thar warehou
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s of types oecific requirle for consid
The use of store and re
• Sma• Hig• Mor
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racking optnsive effecti
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o importantout of the w
Key outbothe outbounortation the
ject Docum
und consist-practice curacy. Howhe warehouuse and the
factor of ths according
xcess good
design of thhe layout d
m benefit fro
of the ren efficient wme of the im
of forklifts, grements of deration.
f conventionetrieve gooaller aisles.her stackingre expensivconvention
der aisles ress expensive
tions shoulive racking
emed too efore exclude
t to take thewarehouse.
ound connd warehourecommend
ment
iderationsregularly pwever dueuse these tcost assoc
he warehoug to the prods, directly
he warehouesign also m layout de
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nal forklifts tds. g ability.
ve. nal forklifts tequired. e.
d be conssolution.
expensive aed and a fe
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s point to m
to the fastechnologic
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se would boduction sch
impacting
use to minimneeds to beesign advan
klifts for thThe cost, rnsideration
s seem to ohouse. Two
to load and
to unload an
idered, alth
and requiredeasible optio
ental impact
ns y acts as akeep the pr
modern techt turnover al advancefore remain
be the propehedule. Inac
the produ
mise the trae effectivelyntages.
he warehoureliability, mto take into
utperform eo material
unload tru
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hough palle
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t into accou
an accumulrocess as b
hnology toand low m
es promise s unwarran
er planningccurate schuctivity and
avel distancey implement
use is a cmaintenanceo account.
electric forkhandling p
cks and spe
llets.
et racking
e implemen
unt when de
lation area asic as pos
P
o increase material vari
little benefnted.
g and schedheduling wod utilisation
e of materiated and enf
crucial parte costs and
lifts with regprocesses a
ecialised fo
should pro
tation and
esigning the
in preparassible.
age | 17
picking iation of fit to the
duling of ould lead n in the
als is an forced to
t of the storage
gards to are also
orklifts to
ovide an
skills to
e lighting
ation for
BPJ 4210 Octo
6 De
The proengineethen fustrategylean stoof the pare wei
After thdepartmallocatethe lean
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To faciover theach de
Table 1: S
0 Final Projober 2012
esign Ap
oject was doering technurther undey that was orage for eqproject, whighed and th
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Systems Engine
ject Docum
pproach
one using aiques to firs
erstanding tused in the
quipment. Tch is whenhe most sui
design folloallocated toent departmesign were
cus on the sign section
analysed equipment.mark the lo
e factory is ibound warehird party m
esign improlife cycle m during the
ering Method o
ment
a top down ast understathe functione project is
The lean sto the plot seitable layou
ws the Suo different aents and thcovered in
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by tracing . The proceocation of thillustrated uehouse will meaning the
ovement prmodel. Theimplementa
over life cycle m
approach wand the neenal require
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pra-level oareas in thehe optimal la
the first pha
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all the inbess was firhe machineusing a flow
not be deae layouts a
rocess the e table beloation of the
model
while implemeds or expements of t
wn approachod first analterions are d.
f the desige plot. A reayout was case of the p
the factory ound, procebound procrst describeery on the p
chart for thalt with in dnd configur
systems eow summarimproveme
menting induected outcothe facility. h which is yses the glostated and
gn, this is elationship chosen. Theproject.
design will ess and outbcess, functioed then a cackaging a
he making odepth in therations are
engineering rises the acent method.
P
ustrial and somes of the
The mainused for deobal view othe availab
when the chart was
e first two s
be broken bound responality, spaco-ordinate rea. The m
of Handy Ane project si
designed
method wactivities invo
age | 18
systems e project n design esigning r design ble plots
different used to tages of
down to ectively. ace and method aking of
ndy. The nce it is by DHL
as used olved in
BPJ 4210 Octo
7 InbTo facidiagramfor the i
Material in
Inbo
und Folklift
Truck
Stores
Prod
uctio
n Planners
Productio
n Folklift
Security
Truck driver
Material
requirem
ent
planne
rs
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uctio
n line
operator
Figure: In
0 Final Projober 2012
bound Militate comm
ms that showinbound raw
flow
truck arrival
Plan Prod
Establish productitarget
bound flow pro
ject Docum
Material Fmunication w the matew and packa
Inbound Truck inspection
Drive to the truck
duction Check shrequi
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requ
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ment
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erial and infoaging mate
Did Truck painspection
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equest material from stores
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request
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k material ability of ted material
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ommended of the flow
mented belo
work
ated Place Mathe
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rial
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d truck pass inspection
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Put materiacorrect plac
Delive
age | 19
to use diagram
ow.
Phase
aterial on rack
Exit
prove material request
al in the ce of use
er to the place of use
BPJ 4210 Octo
7.1.1.1 After th
Produc
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0 Final Projober 2012
Flow diage team revi
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gram correcewed the w
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it passes ts the test ithe require
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through thet then drive
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P
ollows:
ld check av/required le
ate material
e security ges to the unork and wait
to it locatiofore the ma
production pck the availa
age | 20
vailability evel, and
s > pick
gate for nloading t for the
on in the aterial is planners ability of
BPJ 4210 Octo
Material infInbo
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0 Final Projober 2012
flow
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Establish productiotarget
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ject Docum
Inbound Truck inspection
Drive to the truck
uction
Checre
n Plreq
enerate pull list
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ck shift material equirement
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more detaie shown as
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aterial ores
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s material vailable ?
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y step analy
P
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Approve requ
Drive to exit gate
k pass tion
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yes
Put material in thecorrect place of use
Deliver to thof use
ysis of the
age | 21
Phase
on
material uest
Exit
oduction
e e
e place e
inbound
BPJ 4210 Octo
Loaded Truck
Offloaded p
2) Of
After the trulift tomatertaken pallet of ava
4) Placin
The key material idedicated material accumulatitaken to tstored undelivered to
0 Final Projober 2012
1) Vks
allets
ff loading
the driver hasuck in a positioo effectively rial from the
off from the at a time dep
ailable forklifts
ng in Stora
action in this to place or random rahas been
ion area they the area whetil the time o the place of
ject Docum
Vehicle mano
Turning CircleQueuing
Plant layout
Space availableRoad infrastructu
3) Accu
Volumes –Arriv
Loc
Sp
s managed to on that allows
reach and truck, the maside of the trending on the
s.
ge
he delivering material in
ack and after kept in
are ready toere they will when they use.
ment
oeuvring
ere
umulation
– peak trafficval ratecation
pace
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position s the fork
collect aterial is ruck one e number
of n a
the the
o be be
are
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Loaded Trucks
P
ulated pallets
2)
T
Pallets ready for storage
4) Placin
VolumeA
ER
Tructo dthat arrivmandriveoptimmate
) Offloading
Truck arrival patternTruck type
Offloading baysInterface
EquipmentResources
Time
ng in storage
es – peak trafficAllocation
quipmentResources
Time
1) Vehiclecks arrive fromdeliver materia
can be idenves for delivnoeuvring actier tries to posmal position erial from the
3) Accumu
The third noperformed dstaging of thdesignated aspace to accpallets. Threquirement was not posprocess
P
e Al
e manoeuvm the main wal and the fintified when vering materiaion which is sition the vehfor the off-lo
trailer.
ulation
otable action tduring and afthe pallets in tarea. This arcumulate a speis action iwhich could
ssible to avoi
age | 22
Empty truckPallets
llocated pallets
vring warehouse irst action a vehicle al is the when the icle in the oading of
that needs tofter off-loadingthe accumularea will serveecified numbeis an optio
be avoided id in the mak
o be g is
ation e as er of onal but
king
BPJ 4210 Octo
Allocated pa
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f
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A thewh
8) Fe
This the laof raw
0 Final Projober 2012
llets
ets
igure: Inbou
Picking
folk-lift wille pallets froen it is requ
ed Product
step can bast stem in w and packa
ject Docum
5) Stora
Volumes – per fVolumes – per p
Stacking polStorage type/m
Layout
Storage equipmSpace
7) Staging
ScheduleUnit loads
Kit compositionLocation
EquipmentResources
TimeSpace
und flow an
come andom the storauired.
ion Line
be recognistracing the aging mater
ment
age
formatproducticyethod
ment
g
alysis
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sed as inflow
rial.
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Stored pallets
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Returnable packagi
oads
llets
ng
8) Feed p
Delivery-Delivery –Formats/
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Tim
5)
Thefromreqpickfor tworacktimeoptiattr
7) Stag
Stagingtemporthey anormalpallets with thpallets
6) Picking
Schedule
EquipmentResources
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prod. line
distance– location/Productsze
umes
pmentourcesme
Storage
e material is thm the racksuirements for ked and delivethe staging w
o 8 hour shiftsking system es to show imal with speibute
ging
g in this rary locationre put to ully holds ap
of inventohe extreme
which requ
P
Delive
hen stored ans dependingthe shift the
ered. The storwarehouse wos. The design
based on which optio
eed as the m
context refn of the mause. The spproximatelyory for moexclusion o
uire more in
age | 23
Required pallets
ered unit loads
d retrieved g on the material is rage policy ould be for will use a simulated
on will be ain design
fers to theterial before
staging areay one to twoost materiaof the bottleventories.
e e a o al e
BPJ 4210 Octo
InbouThe fowareho
Figure:
The folarea an
1) Truc
Table 2: T
CC's BottlesCaps DividerPoucheOther Raw mats
0 Final Projober 2012
nd procellowing is
ouse.
Actions for
lowing assnd activity in
ck parking • Parking• Trucks
of 2.975• The tru
the max• The tru
Truck Arrival Ra
Total pallets/
s
rs es
ject Docum
ess flow an illustrat
r inbound flo
umptions wn the proces
g/unloading arrive at th5 trucks/houck arrival raximum mateck arrival ra
ate
/12hours
1354324
12
ment
tion of the
ow
where madess:
bays for 4 te inbound wur with peakate is calcuerial flow. ate is calcul
Total pallets/d
3 4 8 2 0 1
expected
e in determ
trucks are awarehouse k times betwulated base
ated as foll
day Pa
2551043
734377
232
173
To
process fl
mining the d
available forover a 23 h
ween 10:00d on the es
ows:
allets/truck
482626262626
26
otal
ow for the
design requ
r simultaneohour period 0 and 12:00stimated ma
Trucks
5.3 40.1 2.8 1.7 3.0 8.9
6.7
68.4
P
e inbound
uirements f
ous unloadat an avera
. aterial flow
Trucks/hou
0.231.7440.120.070.120.38
0.28
2.97
age | 24
material
for each
ing. age rate
and not
ur
1 4 2 2 9 8
9
5
BPJ 4210 Octo
2) Acc
3) Stor
4) Stag
a) Offl
b) Plac
c) Pick
d) Fee
e) Ret
0 Final Projober 2012
cumulation • Pallets • Space
trucks arage • The siz• Initial st
i. ii. iii. iv.
• The folli. ii.
• An addcompen
• Other p15% of
ging • No add• Staging
and cap• All othe• Product
packingoading • Trucks • A forklifcing in stora• Pallets
materia• Materia• The trav
i. ii. iii.
king • All palle• The trav
i. ii. iii.
eding produ• Materiaurn packag
ject Docum
in accumulis allowed fand one 48
ze of pallets tacking regu2 for finishe2 for empty2 for return2 for Caps lowing mateCC’s 3 highRaw mater
ditional safensate for aspackaging mthe total pa
itional stagig space shops stacked er materials ts are all deg lines by au
will be offloft takes on aage will be tra
al. als will be plvel time for 7 minutes fXs for mateetc.
ets will be trvel time for 7 minutes fXs for mateetc. ction
als will be feing and par
ment
ation are stfor 100 pallpallet truck
is assumedulations is ded goods. y bottles. nable packa
erials are toh. rials 3 high.ety margin ssumptions materials suackaging ma
ing equipmeould equal t1 level highwill be stoc
elivered by utomatically
oaded by foraverage 3 m
ansported to
laced in stoforklifts to s
for Bottle paerial Y to lin
ransported tforklifts to p
for Bottle paerial Y to lin
ed into the prtial pallets
tacked up tolets in the a
k.
d to be 1.0mdefined as:
ging.
o be placed
of 40% ismade durin
uch as labeaterial requ
ent is requirthe space reh. cked outsideforklifts to ty or by hand
rklifts. minutes to u
o allocated
rage by forkstore materallets to hanne Z
to the stagipick materiaallets to hanne Z
production li
o 1 level higaccumulatio
m by 1.2m;
in racks:
s added to ng flow calcls and shrinirements.
red. equired to p
e of the mahe staging d.
unload a pa
marked s
klifts. rials is assund Andy Pa
ng area by als is assumnd Andy Pa
ines from th
gh. on area, tot
packagingulations. nk-wrapping
place 1 hou
in storage aarea and th
llet from a t
lots accord
umed to be: ckaging sta
forklifts. med to be: ckaging sta
he staging a
P
talling two 2
g material s
g is accepte
urs’ worth o
area. hen delivere
truck.
ding to the
aging
aging
area by han
age | 25
26 pallet
stock to
ed to be
f bottles
ed to the
type of
nd.
BPJ 4210 Octo
f) Loa
0 Final Projober 2012
• Partial p• 1002 em
and storequirem
• 38 traysby stac
• 544 carstored b
• Cartons• Space i• Space i• Space i
ading return• Returna
deliver • 100 pa• 1002 re• 1 pallet• 11 palle
ject Docum
pallets are rmpty pallets
ored by stacments. s are to be king bundlertons are toby stacking s and lids ais provided is provided is provided able packagable packagmaterials.
allets (10% oeturnable pat of trays reqets of carton
ment
returned to s are to be cking bundl
returned pees to 1 levelo be returnebundles to
re assumedfor 8 hoursfor 8 hoursfor 8 hoursging and exging and ex
of the estimallets requirquire loadinns require lo
storage. returned pes to 2 leve
er shift and l. ed per shift1 level.
d as one un’ worth of re of trays. of cartons.
xcess materxcess good
mate) of excre loading png per shift.oading per
er shift andels high ba
are handled
t and are h
nit and retureturnable pa
rials ds are load
ess goods aer shift.
shift.
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andled in b
ned togetheallets.
ed onto the
are loaded
P
ed in bundleestimated
s of 100 an
bundles of 1
er.
e same tru
for return p
age | 26
es of 10 material
d stored
100 and
cks that
per shift.
BPJ 4210 Octo
7.1.1.2
EquipmentTime
ResourcesSpace
RoadInfrastructure -
spaceInterface
OffloadingBays
RoadInfrastructure –
traffic
Figure 4: C
The diaouputs requirem
0 Final Projober 2012
Overview
8) Feeding production
Combined inbo
agrm=am sof the step
ments for e
ject Docum
w of the inbo
)g
7) Staging
Partial palletsReturnables
ound flow analy
summarisesps in the inach of the s
ment
ound flow
5) Storage
6) Picking
ysis
s the maternbound. Thsteps.
4) Placing in storage
Delivery -distance
Delivery -location
Formats/products -
sizes
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rial the stehe diagram
3) Accumulation
Unit loadKit composition
Location
ps involvedalso show
2) Offloading
Volumes –product/format
Stacking policyLayout
Storage type/methodSchedule
d it shows ws the phys
P
1) Vehicle manoeuvring
all the inpsical and fu
age | 27
Turning CircleQueuing
Plant LayoutTruck arrival pattern
Truck TypesVolumes –peak traffic
Arrival rateLocation
Allocation
puts and unctional
BPJ 4210 Octo
8 SyIn ordeissues ssystemsuse on willattem
The modevelop
Figure 5: S
The momain goprocessthe decdevelop
0 Final Projober 2012
ystems Dr to responsuroundings dynamicsany of the
mpt and inc
odel below iped. It is a
Systems Engine
odel will havoal of the ms when addcisions madping softwar
ject Docum
Dynamicsd to the pro the expect
s model wilir factories.
clude everyt
is a rough smodel that
eering Model
ve some simmodel is toressing thede in a simre intense s
ment
s Factoryoblem of thted levels ol be develo The modething that is
sample of aillustrates t
mple characo address ae productionmpler mansimulation m
y modele unstable
of inventory oped. This mel will be bas neccesary
a model simhe causal re
cteristics ofany issues n and storagner to avo
models.
demand ofthat should
model will based on they for produc
milar to the oelationships
f the similarthat are ne
ge design coid the elon
f the marked be kept inbe customi
e Waterfall ction.
one that thes that are fo
r to the preceeded in thonstraints. ngated wai
P
t and the un the warehzed for Unproject. The
e model thaound in a fa
ceding modhe decision It will help siting period
age | 28
ncertain house, a ilever to e model
at will be ctory.
del. The making
simulate ds when
BPJ 4210 Octo
8.1 MThe flosuccessparamewhich isdata thfunction
Differen
0 Final Projober 2012
Modellingw chart besful system
eters will bes to determhat was cons will be us
nt simulation
ject Docum
approacelow showsms dynamice determineine the rang
ollected throsed to in co
n results wi
ment
ch the steps
cs model. Ted using indges for the ough informnjunction w
ll be genera
Figure 6
that are foThe first stedustrial engparametersmal time a
with the rand
ated by allo
6: Simulation a
ollowed wheep which isineering tecs and distriband motiondom functio
wing differe
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Diffebe diffeordeunemacabse
P
ping in desimine the simnd the secobe estimate
hereafter sexcel functi
on scenario
erent simugenerated
erent produer sizes axpected va
chine failuenteeism
age | 29
igning a mulation ond step ed using tatistical ons.
os:
lation resuby implem
uction and and also inariation indu
res and
ults will menting varying ncludes uced by
worker
BPJ 4210 Octo
8.2 AThe moand excprocesshow mu
Figure 7: C
The abfollowused
Figure 8: S
The simin the packag
0 Final Projober 2012
Analysis podel will be cludes soms steps in ouch waste is
Causal relation
ove diagrawing diagrad in analysin
Stock and flow
mulation moappendix. ing and pro
ject Docum
parametebased on t
me of the faorder to highs produced
nship diagram
m above sam is a mong the produ
w diagram
odel depicteThe mode
ocessing ma
ment
ers of the he productiactors incluhlight the ain productio
hows the cdified versiuction and p
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model on sector m
uded in themount of mon.
causal relaton of the mprocessing
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d stock andand output
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odel in the fve. It has behandy Andy
d flow diagraprocesses
P
ed to excludude the prohine and to
factory modeen modifiey product lin
am will be iand steps
age | 30
de some oduction indicate
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BPJ 4210 Octo
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No of bottle
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nventory ing a warehexpected inproduced inon the sysaims to simrequiremencs model.
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Analysingbottles usedThe graphed for a pe
mption and entory was was used or
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60
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1 8 15
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ject Docum
Calculatihouse for anventory levn the factorstems dynamulate the mnts will be
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15 22 29 36 43
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162
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age | 31
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8.3.2 The gra(64 x2)
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30
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Loading baph shows of 128 palle
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1 4 7 10
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age | 32
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8.3.3 This grcaps an
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Rack spacraph which nd the wrap
15 29 43 57 71
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age | 33
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age | 34
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8.3.5 The gramateria
Figure 13:
The valthen latThe tota
Figure 14:
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Raw Mateaph below
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age | 35
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8.3.6 The grwarehoassumein the raracks amateria
Figure 15:
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Total Numraph belowouse for dured that theyacks. The
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: Total materia
Analysis oaterial usedr of pallets r of racks es it would ckaging ma
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181
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age | 36
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BPJ 4210 Octo
8.3.8 With a truck thinventoAndy m
Figure 16:
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Empty palschedule o
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age | 37
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8.4 WAfter throutingsimproveamountunloadi
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8.4.1 • • • •
8.4.2 1.
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Warehoushe expecteds of the woes the flowt of materiang dock to
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age | 38
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BPJ 4210 Octo
8.4.4 The follresearclayout f
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0 Final Projober 2012
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age | 39
roven by fishbone he isles.
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