Primarius Warehouse Optimisation
 
 

"The full operational
efficiency of a warehouse
can only be achieved
when it has the ability
to deliver in full,
on time to customers"

Warehouse Optimisation
Warehouse Optimisation
There are normally two major constraints on a warehouse’s performance –

      1. It is not efficient due to not having the right products in stock and too much of the wrong products (i.e. dead           or slow moving stock) is filling up the space, or

      2. The design, layout, equipment or manning levels of the warehouse are not adequate.

The full operational efficiency of a warehouse can only be achieved when it has the ability to deliver DIFOT (Delivery In Full, On Time) to customers. Inventory issues such as out of stocks, obsolete stock and overstocks can rob the warehouse of efficiency and lead to increased labour costs, materials management costs and distribution transport costs. No matter how much money is spent on racking and forklifts, a warehouse will not be efficient if it is not storing the ‘right’ products in sufficient quantity to meet customer orders.

Primarius can provide a unique optimisation of warehouse layouts and performance. Through its OMS toolsets, Primarius is able to examine the upstream inputs into the warehouse – forecasted sales, the volume and frequency of order receivals and customer orders requiring dispatch – to gain a thorough understanding of likely future performance requirements as well as being able to determine what is holding back the warehouse’s performance today. This could be the continual non-supply of critical parts or the abundance of dead or slow moving stock taking up valuable space and resource.

Primarius can utilise this information to improve upstream performance which will provide the warehouse with improved operating conditions. Then a focus on the warehouse’s design, layout, equipment and manning levels can be conducted without being diverted by the upstream supply chain issues.

Primarius uses a combination of process modelling and optimisation tools to examine –

• Production outputs

• Warehouse capabilities to receive and store both raw and finished goods, including racking type and     utilisation

• Transport constraints – whether they be vehicle types, frequencies, capacities or dock sizes

• Material handling capabilities including the type and nature of forklifts required

• Manual handling requirements covering
       o Vehicle load and unloading
       o Product check in and put away
       o Full and part picking and
       o Value added services required.

• Manning and supervisory requirements

Some examples of modelling conducted –
Projected Activity Levels Projected Activity Levels
Modelling of Batch Production

Modelling of batch production
capabilities of the Factory

OMS Toolsets OMS toolsets used to forecast demand
and pallet positions required could be
determined
The diagram below is a screen shot of the simulation display. The diagram shows task queues for each activity as well as utilisation data for resources.
warehouse Simulation
'Arena' simulation of warehouse with various combinations of
MHE analysed
The warehouse layout is then modelled using simulation toolsets to examine its capability to handle these loads. Handling equipment, racking types and locations and work practices are examined and modelled to improve performance.

Detailed analysis of the warehouse is examined and optimised –
  Warehous analysis
    •  Block Stack
Modelling of combined activities carried out - Goods In, Handling, Vehicle Movements, Transport Modes, Distribution variations - assessed to determine viability
of models
To give detailed understanding of future requirements -
  Projected Pallet Holdings Projected Pallet Holdings
 
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