crossdocking仓储管理越库配送

WarehousingSystemsCrossdocking2IssuesCrossdockingIssuesCrossdockShapeCrossdocklayout3WarehousingfunctionsRecallthatwesaidthatthefourkeywarehouseareasare:•receiving•storage•orderpicking•shippingStorageandorderpickingtendtobethemostcostlyoperationsduetolaborandspacerequirementsCrossdocksattempttoprovidereceivingandshippingoperationswhileeliminatingtheneedforstorageandorderpicking.4CrossdocksAreusedtotransferincomingshipmentsdirectlytooutgoingtrailerswithoutinstorageinbetween.Shipmentstypicallyspendlessthan24hoursatthefacility,andmanytimeslessthananhour5AtypicalI-shapecrossdock6ExampleReceivingShippingSorting7Crossdocks----avarietyofshapes8Crossdocks----avarietyofshapes9ComparisontotraditionalwarehouseInatraditionalwarehouse:•Goodsarereceivedfromvendorsandstored(e.g.palletracksorshelves).•Whenacustomerrequestsanitem,workerspickitfromstorageandsendittotheappropriatedestination.Inacrossdock,goodsarrivingfromthevendoralreadyhaveacustomerassigned,soworkersneedonlymovetheshipmentfromtheinboundtrailertoanoutboundtrailerboundfortheappropriatedestination.10Howmanytimes“touched”?ShippingCustomerReceivingReceivingPutawayStoragePickingShippingDirectShipTTCrossdockTTTTDirectputawayTTTTTTTraditionalTTTTTTT11AboutPutawaytheprocessthatmovesmaterialfromthereceivingareatostorage,replenishment,pickareas,orevenstraightintomanufacturingoperationThreeoptionsforhandlingputaway:1.unloadfromthetrailerandmoveitemstostorageormanufacturingafterconfirmingthereceipt2.groupshipmentsbyitemduringthereceipt3.directputaway,movingitemsdirectlyfromthetrailertoitsdestinationonthebasisofASN(advancedshipmentnotice)12Pre-andpost-distributionInpre-distributioncrossdocking:•customersareassignedbeforetheshipmentleavesthevendor•shipmentarrivestothecrossdockreadyfortransfer(e.g.properlabelsalreadyplaced).Inpost-distributioncrossdocking,thecrossdockitselfallocatesmaterialtoitsstores.•Forexample,acrossdockataWal-MartmightreceiveseveralpalletsofTidedetergentwithoutlabelsforindividualstores.Workersatthecrossdockallocate3palletstoStore23,5palletstoStore14,andsoon.13Pre-andpost-distributionPre-distributionhastheimplementationdifficultyofknowingwhichcustomersofthecrossdockneedbeforetheshipmentissent•HighITcapabilityisrequired!•Highcoordinationinfrastructurerequired!•VerydifficulttosolvewithmanycustomersandvendorsPre-distributionhasthebenefitofreducinglaboreffortatthecrossdockandhencereducingspace/laborrequirements14CrossdockstatisticsIn2000,therewereapproximately9,000crossdocksintheUSandCanadaThelargestLTLcarriersspendabout$300Mto$500Mannuallyhandlingfreight(about20%oftotalcosts)andoperateonveryslimprofitmargins(veryfewofthelargestcarrierspostedanannualprofitofover2%overthepastseveralyears)Forexample,Wal-Martconsideredcrossdockingacorebusinesspracticesinceearly80s15Example-distributes2typesofproductsfromDCs:•staplestock-itemsthatcustomersexpecttofindatthesameplaceateverystore,andthatsoldeachdayoftheyear(e.g.detergent,toothpaste,jeans,etc.)•directfreight-stockthatcentralbuyersprocureinlargequantitiesandpushouttostoresineachDCthereisaninventoryofstaplestockwhicharepickedandshippedonrequest16Wal-MartcontinuedDirectfreightitemsarehandledmuchdifferentlyfromstaplestock:•arriveonpalletsplacedimmediatelyonflowracks•workerspickcasesontheotherside•Wal-Mart’scentralinventorysystemdetermineshowmucheachoutletreceives•directfreightisinthewarehouseforlessthan48hours(soinventorycostsgreatlyreduced)17TypesofCrossDockingManufacturingCD:receivespurchasedproductsrequiredbymanufacturing,wherepreparingsub-assembliesfortheproductionordersmayinvolveDistributorCD:consolidatesinboundproductsfromdifferentvendorsintoamixedproductpallet,thendeliverstothecustomerTransportationCD:combinesshipmentsfromdifferentcarriersintheless-than-truckload(LTL)andsmallpackageindustriestogaineconomiesofscale18TypesofCrossDockingRetailCD:receivesproductsfrommultiplevendorsandsortsontooutboundtrucksforanumberofretailstores(WalMart)OpportunisticCD:Thiscanbeusedinanywarehouse,transferringaproductdirectlyfromthegoodsreceivingdocktotheoutboundshippingdocktomeetaknowndemand,i.e.acustomersalesorder.19Whichitemstocrossdock?SingleSKUunitloads(palletorcarton)BackordersInter-DCtransfersCustomer-readyloads20Whichitemstocrossdock?PerishableitemsthatrequireimmediateshipmentHighqualityitemsthatdonotrequirequalityinspectionsduringgoodsreceiptProductsthatarepre-tagged(barcoded,RFID),pre-ticketed,andreadyforsaleatthecustomerPromotionalitemsanditemsthatarebeinglaunchedStapleretailproductswithaconstantdemandorlowdemandvariancePre-picked,pre-packagedcustomerordersfromanotherproductionplantorwarehouse21CrossdockenablersAutoID,e.g.,AdvancedShippingNote(ASN)Real-timecommunicationsInboundreceivingschedulingDockmanagementsystem22CrossdockingBackgroundDistributedMovement--Packagesareconveyed,sorted,anddivertedtoappropriateshippinglanesConsolidatedMovement--MerchandiseisreceivedinpalletorunitizedformbutmustbestagedandconsolidatedwithotherproductgenerallyfromaconventionalpickingoperationUnitized