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Logistics Management > Order Picking Assembly > Flashcards

Order Picking Assembly Flashcards

1
Q

Functions

When is storage enough in a WH?

A

When
In-flow = Out-flow

No transformation is needed

Rare

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2
Q

When is picking needed in a WH?

A

when
Inflow different than outflow

Most likely

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3
Q

What is the Order Cycle?

A

Order processing+
Order Assembly+
Delivery

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4
Q

Within the Order Cycle,
What is Order Assembly?

A

Collecting the items = picking being the core activity

Process:
1. Picking list production
2. Picking
3. Sorting
4. Packaging
5. Transport Load Consolidation

Connection 1-2=picking list

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5
Q

Define better Picking

A

Selective retrival of unit loads from high level UL to prepare custumers orders

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6
Q

Tell me the 3 types and main characteristics of Picking types:

A
  1. Layer: full cartons layer
  2. Carton picking: specific cartons
  3. Pieces picking: from cartons
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7
Q

Design Variables/Parameters

Mention the 2 of them

A

SC
TC

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8
Q

How could be divided the SC

A

In reverse and forward storage

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9
Q

The SC is confomed out of which type of stock

A

Cycle stocks and Safty stocks

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10
Q

Forward Reserve Problem

A

How to split the capacity between reserve and forward stocks.

Internal decision tradeoff between
1. Picking efficiency
2. cost to transport from R to F

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11
Q

Picking Key Performance Indicators

Cost related:

A

Replenishment
Picking
Sorting
Packing
Labour
Space
Equipment
Systems

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12
Q

Picking Key Performance Indicators

Customer service

A

Accuracy
Order Picking cycle time
Flexibility

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13
Q

Whats the impact of order assembly in:
1. WH cost
2. Customer Service

A
  1. 50% WH cost = Order assembly (picking)

Complexity (fragmentation of units) and Labor intensity (difficult to automate)

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14
Q

Picking process

Activities

A

Picking
Sorting
Packaging

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15
Q

Picking process

Resource

A

Labor
Space
Equipment

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16
Q

Picking performance measurement

We said Cost & Service Level,
Develop on the SL KPIs

A

Picking accuracy: related to order accuracy/compliance
Picking Cycle Time: Part of the Order Cycle Tyme
Picking Flexibility: ability to adapt to changes
Picking Punctuality: On time deliery

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17
Q

Picking Systems

Mention the different Picking Systems

A
  • Pickers to Parts
  • Pick to box
  • Pick and sort
  • parts to picker
  • Automated picking
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18
Q

Explain the Diagram Picking Systems

A

Who pick goods?
Machines: Automated picking
Humans: Who moves in the picking area?
Goods: parts to pickers
Pickers: convoyers connect picking zones?
No: Picker to parts (item/Order)
Yes: Order=Pick to box, Items=pick and sort.

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19
Q

Picking Systems

Picking Policy of:
Picker to parts
Pick to box
Pick and Sort

A

Pick by Item/Order
Pick by order
Pick by item

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20
Q

Picking Systems

The picker carries out a “picking mission” within the “picking area”, visiting in sequence all the locations which are detailed in the “picking list”

A

Picker to parts

I need structures racks, shelves, drawers

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21
Q

Pickers to parts

Explain how is this system conformed

A

Picking area (Configurated 2D, 3D)
Pickers (>1)
Picking mission: multiple-command mission (touch as many points) TPS: Traveling Salesman Problem

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22
Q

Pickers to parts

How is Picking mission time conformed

A

Picking mission time is the time a pickers take for one mission considering travel time and retrival time.

PMT= TT + RT

Different from Picking cycle time or Picking lead time

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23
Q

Pickers to parts

Design/management decisions

How do you decrease Travel Time TT

A

Reducing Area

or

Management pollicies
* Routing (sequence)
* Storage (allocation)
* Batching

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24
Q

Pickers to parts

Design/management decisions

How do you decrease Retrival Time RT

A

ICT Information Comunication Tech
Allocation of products

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25
Q

Pickers to parts

How is it in terms of:
* Labor productivity
* Space Productivity
* Investment (CAPEX)
* Reconfiguration (flexibility)
* Accuracy & Speed

A
  • Labor productivity:
    –/-Low (high OPEX), safty, security, compliance issues. (automatic suport helps)
  • Space Productivity:
    —Low
  • Investment (CAPEX): Low (high OPEX)
    +++ low investment
  • Reconfiguration (flexibility)
    +++ high flexibility
  • Accuracy & Speed
    –/- Low acuracy (bar codes helps)
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26
Q

Picking Systems

These 2 systems have a Picking Area, Picking Zones dedicated to pickers and conveyors

A

Pick to box (order)
Pick and sort (item)

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27
Q

Conveyor

A

mean of integration
Conects zones

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28
Q

Picking system

Pickers pick the items and put them in a box, one box per order

Picking and sorting toether

A

Pick to Box

29
Q

Picking system

Pick and sort

A

Items picked are directly placed into the convoyer no box and then you have a sorting area/task.

30
Q

Pick to box / pick and sort

Management decisions

A

No. Zones
Zones Balancing
Storage policies
Batching policies)
Sorting (manual automated)

31
Q

Pick to box / pick and sort

How is it in terms of:
* Labor productivity
* Space Productivity
* Investment (CAPEX)
* Reconfiguration (flexibility)
* Accuracy & Speed

A
  • Labor productivity:
    +high (workers know the area)
  • Space Productivity:
    – low
  • Investment (CAPEX): Low (high OPEX)
    -high due to convoyers or machines
  • Reconfiguration (flexibility)
    -low
  • Accuracy & Speed
    -Unrelaiability risk
32
Q

Picking systems

The aim is to eliminate Travel Time
There is a storage area + handling system+ picking area

The UL (big or small) is brought to the picker who takes the item(s) and the rest is sent back.

A

Parts to pickers

33
Q

Parts to pickers

Design management issues

A

Handling system design
Ergonomy of picking station

34
Q

Parts to pickers

How is it in terms of:
* Labor productivity
* Space Productivity
* Investment (CAPEX)
* Reconfiguration (flexibility)
* Accuracy & Speed

A
  • Labor productivity:
    ++high (xTT)
  • Space Productivity:
    ++Picking dedicater area
  • Investment (CAPEX): Low (high OPEX)
    –high due to chandling system
  • Reconfiguration (flexibility)
    –low
    -KIVA solution
  • Accuracy & Speed
    ++ high
35
Q

Picking system

Machines robots instead of humans
Robots to parts
Robots to convoyers
Part to robot

A

Automated picking system

36
Q

Picking system

Rank Order pikcing systems so that is true that:
* Labor productiviti increases
* Space productivity increases
* Accuracy/ speed increases
* Investment (CAPEX) increases so benefit decreases
* Flexibility decreases

A
  1. Picker to parts
  2. Pick to box
  3. Pick and Sort
  4. Parts to picker
  5. Automated
37
Q

Logical Flow chart

A

Descriptive tool of WH flows

38
Q

Pickind Design Management

How to set a problem?
What to consider

A
  1. Objective Function:
    Cost & Service
  2. System Capacity
    Throughput Capacity
  3. Data
    Order / Item profile
39
Q

Pickind Design Management

Design & Management decisions

Once we have the inputs of a Picking system in which iteration it enters?

A
  1. Picking system selection
    1.1 Picking sub-problems
    1.2 Picking Sub-problems solutions

2.System(s) capacity & design
2.1 Storage Capacity
2.2 Layout configuration

3.Management policies

40
Q

Problem setting

When talking about the Order profile how can we dimension it:

A

Volumes: Lines/Order
Volumes: Volume/Order
Picking Units (UL, caron,…)
Volumes: Palletised UL

41
Q

Problem setting

How can we clssify the SKUs (items)

A
  • Frequency (order/lines/time)
  • Volume
  • Weight
  • Fragility

Pareto always a good idea= cumulative curve

42
Q

Design & Management decisions

  1. Selection of the picking System
A
  • Segmentation of the picking problem in sub-problems
  • Identification of elegible picking solution(sub)
43
Q

Design & Management decisions

  1. Picking System Capacity and design
A
  • Picking system Capacity (forward-reserve solution)
  • Picking System configuration (layout)
44
Q

Design & Management decisions

Management Policies

A

Space allocation
Patching
Routing
Location/storage

45
Q

Design & Management decisions

I have to Design and define policies for all the sub-problems found?

A

Yes, is an iterative process.

46
Q

The Forward - Reserve decision

A

How to split the overall inventory within the warehouse into a reserve stock and foreward stock (inventory dedicated to picking)

47
Q

The Forward - Reserve decision
Output

A

The output is the Storage Capacity of the Picking System.

48
Q

The Forward - Reserve decision
Subproblem

A

Embedded problem: Space allocation problem.

Allocation of the overal space (S) to single items (Si) in order to reduce the number of replenisments (R) from reserve to forward area.

49
Q
A
50
Q

The Forward - Reserve decision
Basic Trade-off

A

Basic trade off= replenishment cost and picking cost

51
Q

Compare pros cons general and picking stock

General Stock
RS = PS

A

+No replenishment
-Picking efficiency decreases

52
Q

Compare pros cons general and picking stock

Picking stock
RS>PS

A

+Picking efficiency increases
-Replenishment

53
Q

space allocation problem od RSFS

Function and graph of TC(S)

A

TC: Total cost
S: Picking Stock capacity (stock)

TC=CPicking(s) + CReplenishment(s)

The TC cost is the sum of Cpicking and Creplenishment.

The Cpicking is a curve that increases as S increases
The CReplenishment is a Curve that decreases as s increases
Where Cpicking and Creplensiment intersect is the optimal S and the value of the TC of that point says the cost.

54
Q

FRP

Items replenishes at same frequency
Storage capacity depends on replenishment frequency
less frequent = more space
Items volume flow is considered

Pro: cost to optimize the replenishment process
Con: Complex to allocate space and design layout
If location = size, no good saturation

A

Equal time supply

55
Q

FRP

Each item have same volume
itemv = V/N
Replenishment freq is different
freq=flow/volume

pros: cost to allocate space and design layout
cons: cost to manage replenisment complex

A

Equal space

56
Q

FRP solutions

Min(R)
Complex to allocate space and manage the replenishments

A

Optimal solution

57
Q

Picking Management Policies

Picking management main 3 policies

A
  1. Storage
  2. Batching
  3. Routing
58
Q

Picking Management Policies

The basic decision is to increse the picking density

A

Batching Policy

59
Q

Picking Management Policies

Batching

What are the main decisions when Batching

A
  1. Sorting:
    while pick (few orders)
    ater pick (manual automatic)
  2. Batch Size
    Trade-off between Sorting Time and Picking time per order (Nopt)
  3. Batching logic
    Delivery date
    Physical proximity
60
Q

Picking Management Policies

Batching Pros/Cons

A

Pros:
Increase picking density
Reduce picking time
Increase orders’s lines overlaping
Set up time reduction

Cons:
Sorting!!!
Information intensive approach

61
Q

Picking Management Policies

The basic decision is about the sequence of picks

The objective is to minimize the travel of the picking mission (Input-Locations-Output)

A

Routing policies

Traveling Salesman Problem

62
Q

Picking Management Policies

What are the possible taken approaches for routing

A
  1. Order by Order
    Each order is routed to min travel
  2. Pre-defined
    A pattern choosen once for all (stable, easy to apply other policies but travel not min)
    a) Traversal policy
    b) Return Polic
63
Q

Picking Management Policies

Pros and cons Routing

A

Pros:
Picking productivity (as for all the others)
Decrease travel time

Cons:
Dynamic
Complex in an operational way

64
Q

Picking Management Policies

The basic decision is about the allocation of a single itmens or classes of items in oicking locations

The main trade of is picking cost - operational complexity (congestion)

Increse density of proximity

A

Storage policies

65
Q

Picking Management Policies

Storage policies 3 main classes

A

Random Storage
Picking travel = Access Index
Picking Time = Correlated Storage (items to be highlikly to be ordered together)
Operational needs

66
Q
A
67
Q

Picking Management Policies

Storage

The item with higher ratio between Picking Frequency and dedicated space go closer to the I/O.

Reducing Picking time, increasing congestion and it is dynamic

It needs to consider the routing policy

A

Access index based

Traversal decrease aisles visited
Return decrease visited lenght

68
Q

Picking Management Policies

Pros and cons of storage

A

Pros:
Picking productivity (as for all the others)
Decrease travel time
Decrease retrival time

Cons:
Dynamic

Logistics Management (6 decks)

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