Warehousing

Function
Storage in Transit Inventory

Economic Service
– Consolidation & Break Bulk - Spot Stocking
– Assortment - Full Line Stocking
– Postponement - Product Support
– Stockpiling - Market Presence
– Reverse Logistics
 Consolidation & Break Bulk
 Reduce Transportation Cost by using
warehouse capability to increase
shipment economic of scale
 Consolidation, warehouse receives
materials from number of sources which
combined into a large single shipment
to a specific destination
 Break-Bulk, operator receives a single
large shipment and arrange for delivery
to multiple destination
 Consolidation

Plant A

Consolidation
Plant B Warehouse
X Y Z

Plant C
 Break-Bulk

Customer X

Break-Bulk
Plant A Customer Y
Warehouse

Customer Z
 Assortment
Reconfigure freight as it flows from origin to destination

Cross Docking Mixing Assembly

 Cross-Dock
Combine inventory from multiple origins into an assortment
for specific customer
Plant A Customer X

Distribution
Plant B Customer Y
Warehouse

Plant C Customer Z
 Mixing
Customer W
A B C D
Plant A
Customer X
A B C D
Transit Mixing
Plant B Point Customer Y

Product D A B C
Customer Z
Plant C
A B
 Assembly
Procure inventory from multiple Vendor to
support manufacturing operations
Vendor A

Lead Supplier
Vendor B Assy. Plant
Warehouse

Vendor C
 10

Postponement
Warehouse postpone commitment to final
product configuration by completing
final packaging, labeling, and light
manufacturing

Reduced Risk Lower Inventory

 11

Stockpiling
Accommodate seasonal production or demand

Buffer Stock
 12

Reverse Logistics
Perform physical work related to product
recall, reclamation, disposal of
overstock and damage inventory

Control Regular
 13

Service

Establishing warehouse to service a specific

market area

- Spot Stocking
- Full Line Stocking
- Product Support
- Market Presence
 14

Spot Stocking

 SpotStocked in a Local Market Warehouse in

Anticipation of Responding to Customer Need
During the Critical Sales Period Rather Than
Maintaining Inventory in a Warehouse Year-
round

 Usetemporarily Warehouse for Time Limited

Period
 15

Full Line Stocking

 Warehouse can provide one-stop
shopping capability for goods from
multiple manufacturers

 Use Permanent Warehouse for

Unlimited Time Period
 16

Production Support
 Stock
Inventory to Support Manufacturing
Operation

 Support
Warehouse Containing an Inventory of
Processed Materials, Components and
Subassembly
 17

Market Presence

 Respond faster to customer needs

 Increase Market Share and Profitability

 18

Warehouse Operation
The objective is to efficiently receive
inventory, possible store it until required
by the market, assembly it into complete
orders, and initiate movement to
customer

Handling Storage
 Receiving - Active
 In Storage Handling - Extended
 Shipping
 19

Warehouse Ownership

Private Public Contract

 20

Warehouse Size

 Min = SSL +Q

 Max = SSL+T + Q
Flow of Goods in Warehouse

Receiving

Holding

Picking

Shipping
Flow of Goods in Warehouse
Receiving Receiving Receiving

Holding Holding Holding

Picking Picking Picking

Batch Forming

Packaging

Shipping
 Storage Media
 Physical Characteristics of Goods in
Stock
– Solid Goods: Stack, Rack, Drawers
 Number of items of each product in a
customer order
 24

Storage Plan
Receiving Dock

Low Volume High Volume Low Volume

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Shipping Dock
 Storage/Retrieval Transport
1. Picker to Product System
• A team of human order pickers, traveling to
storage location
2. Product to Picker System
• An automated device, delivering items to
stationary order pickers
• AS/RS
Block Stacking System
 Item Retrieval by Trolley
y

x
 A/R Machine
Side aisle

Central aisle
Item Storage and Retrieval By AS/RS
and Belt Conveyor
Side aisle
 Location and Site
Criteria

Services Operating Cost

 Faktor Lokasi

1. Pasar Dan Bahan Baku

Jasa Semen

Fragile Kertas

Berat Agro Industri

SERVICES COST
 Faktor Lokasi

2. Tangible
. Transportasi . Utilitas
. Tenaga Kerja . Biaya Konstruksi
. Energi . Pajak
. Tanah . Bahan Penolong
. Insentif . Dll
 Faktor Lokasi

3. Intangible
– Iklim
– Peraturan
– Stabilitas Politik
– Kemudahan Ekspansi
– Budaya
– Polusi
– Dll
Tahapan Pemilihan Lokasi

Regional

Makro

Community

Mikro

Site
 Metoda Pemilihan
 Gravitasi
 BEP
 Transportasi
 Point Rating
 Simulasi
 Metoda Gravitasi
 Minimasi Ongkos Transportasi
 Faktor Faktor Lain Tetap
(Sama Untuk Semua Pilihan Lokasi)
 Menggunakan Koordinat Cartesian
Sebagai Basis
 Formula Metoda Gravitasi

J = Ti Bi Ji /Ti Bi
Dimana:
Ti : Biaya Transport Dari Tiap Titik i Ke Lokasi
(Rp/satuan /Km)
Bi : Berat Yang Diangkut Dari / Ke Lokasi i
Ji : Koordinat Dari Titik i
Contoh Metoda Gravitasi
Data pasar
– A : 10 ton; 5000/ton/km

– B : 2 ton; 8000/ton/km

– C : 8 ton ; 4000/ton/km

Koordinat:
– A (13, 22) ; B (95,84) ; C (118,41)
 Contoh Metoda Gravitasi
 Jx = (5x10x13) + ( 8x2x95) + ( 4x8x118)
(5x10) + ( 8x2) + ( 4x8)
= 91,3 KM

 JY = (5x10x22) + ( 8x2x84) + ( 4x8x41)

(5x10) + ( 8x2) + ( 4x8)
= 38,3 KM
 Metoda BEP
•Faktor Yang Lain Tetap ( Sama )
•Fix Cost Dan Variable Cost Berbeda
A

B
 Metoda BEP
Total Cost Lokasi A = Total Cost Lokasi B

FA + Q. VA = FB + Q.VB

Q = (FA - FB )/ (VB - VA )
 Metoda Transportasi

 MultiLokasi
 Faktor Lain Sama Kecuali Ongkos
Transport
 Metoda Point Rating

 Menggabungkan Faktor Tangible &

Faktor Intangible
 Menggunakan Pendekatan Kwalitatif
Dan Kwantitatif
 Prosedur
 Identifikasikan Faktor Yang Relevan
 Tentukan Bobot Setiap Faktor
 Tentukan Rating Faktor Pada Setiap Lokasi
 Hitung Bobot Score Pada Setiap Lokasi
Untuk Setiap Faktor
 Jumlahkan Bobot Skor Pada Setiap Lokasi
 Pilih Lokasi Yang Memiliki Skor Tertinggi
Contoh
Warehouse Design
Criteria

Services Cost
 Warehouse Cost

 Receiving Cost
 Holding Inventory Cost
 Retrieving Cost
 Assembling to customer order Cost
 Shipping Cost
 Factors To Be Considered

 Physical characteristics of products

 Number of items in stock
 Rate of storage and retrieval request
 Warehouse Design
1. Determining the capacity: length, width and
height
2. Locating and sizing: receiving, shipping and
storage zones (including number of I/O port,
number, length and width of the aisles of
storage zone and the orientation of
stack/racks/drawers)
3. Selecting the storage medium
4. Selecting the storage/retrieval transport
mechanism
 50

Basic Warehouse Design

Receiving Area

Bulk Storage Rack Storage

Area Area

Order Picking Area

Packaging or Unitizing Area

Staging Area

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Selecting The Storage/Retrieval
 Physical
Characteristics of goods
 Packaging at the arrival
 Composition of out going lots

Stack Rack Drawers

 Sizing Receiving &Shipping
The Number of Truck Dock

ND = [dt/QT]

ND : Number of Dock Truck

d : Daily demand from all order
t : Average time required to load/unload a truck
Q : Truck Capacity
T : Daily time available to load/unload a truck
 Example
Average daily demand is 27.000 units, outgoing
shipment are performed by trucks, with capacity
equal to 850 units. Average time to load a truck is
280 minutes and 15 working hours are available
every day

Number of dock truck:

ND = [d.t/Q.T]
ND = [27.000x280/850x(15x60)]
ND = 10
 Storage Policy
1. Dedicated Storage policy:
– Product is assigned at pre-established set position
– Easy to implement but causes an under utilization
2. Random Storage policy:
– Product allocation is decided dynamically on the basis of:
 Current warehouse occupation
 Future arrival and request-forecast
– Allow a higher utilization of space but requires:
 Each item be automatically identified
 Update database of current position of all items
 Storage Policy
3. Class Based Storage policy:
– Product are divided into a number of
categories according to their demand
– Each category is associated with asset of
zones where the goods are stored according
to random storage policy
 Sizing of Storage Area
 Dedicated Storage policy:
n

MD = ∑ max Ij(t)
j=1

MD : Number of required storage location

Ij(t) : Inventory level of item j at time t
n : Number of item

 Random Storage policy:

Mr = max∑ Ij(t) ≤ MD
 Example of Storage Area
Product Lot Safety Stock
A 500 100
B 200 80

 Dedicated Storage policy:

MD = ∑ max Ij(t)
= 600 +280 = 880

 Random Storage policy:

Mr = max∑ Ij(t) ≤ MD
= 600 + 180 = 780
 Length and Width of Storage
Length: Lx = ( ax + ½ wx )nx
Width : Ly = ( ay ny + wy )
Dimana:
ax : Occupation of a unit load along the direction of x
ay : Occupation of a unit load along the direction of y
wx: Width of side aisle along the direction of x
wy: Width of side aisle along the direction of y
nx: number of storage location along the direction of x
ny: number of storage location along the direction of y
A Traditional Storage Zone

Wx

Wy Ly

Lx
 Model of Sizing The Storage Zone
Minimize:

 1  n x  y n y  wy
  x  wx  
 2  v 2v

Subject to:
nx n y nz  m
nx n y  0,integer
 Determining nx and ny
 Number of Storage Location Along Y Direction

2 m x  12 w x 
n'y 
 y nz

 Number of Storage Location Along X Direction

m y
n'x 
2nz  x  12 w x 

nx  n'x  and  
n y  n'y
 Example
Berapa ukuran luas gudang untuk menampung produk A
dan B diatas jika:
1. Jika setiap pallet produk A dan B memiliki dimensi yang
sama dan memerlukan 1.05x1.05 m2 area.
2. Barang akan diletakkan diatas rak dimana setiap raknya
terdiri atas 4 tingkat.
3. Lebar gang utama adalah 4 m dan gang lainnya 3,5 m
4. Cara penempatan barang dengan menggunakan random
policy
 Example

780 1.05
n' x   6.05
2  4  1.05  32.5 
2  780  1.05  3.5
  32.25
n' y  2
1.05  4
 Example
•nx = 6 and ny = 33
•Length: Lx = ( ax + ½ wx )nx
= ( 1.05 +(3.5/2))x6
= 16.8 m
•Width : Ly = ( ay nx + wy )
= (1.05x33+4)
= 39.65 m
 Case
 Suatu sistem logistik terdiri atas satu unit produksi,
satu depot dan 10 agen. Unit produksi berkapasitas
100.000 unit per tahun, ongkos set up sebesar
Rp.25.000.000/set up dan ongkos simpan pada
eselon produksi sebesar Rp. 20.000/unit/tahun,
waktu pengiriman barang dari unit produksi ke
depot 1 bulan sedangkan dari depot ke rertailer
ditunjukkan pada tabel berikut. Ongkos
pemesanan dari depot ke unit produksi sebesar Rp
1000.000/pesan, dan ongkos transport dari unit
produksi ke depot sebesar Rp. 50.000/unit,
sedangkan ongkos simpan pada eselon depot
sebesar Rp.40.000/unit/tahun. Adapun data pada
agen ditunjukkan pada tabel berikut
 Data Pada Agen

Agen Aj Hj Bj Dj Sj Ldj Cdj

j Rp/Psn Rp/unit/thn Rp/unit unit/thn unit/thn thn Rp/unit
1 50000 4000 50000 5000 500 0.05 9500
2 40000 6000 50000 4000 400 0.03 8000
3 30000 8000 35000 4500 500 0.10 9000
4 60000 10000 40000 5000 500 0.10 8000
5 75000 12000 40000 6000 600 0.05 6000
6 65000 8000 30000 5500 550 0.05 6000
7 70000 10000 40000 6000 600 0.10 9000
8 60000 8000 45000 5000 500 0.05 6000
9 55000 12000 50000 4000 400 0.05 6000
10 70000 8000 40000 5000 500 0.03 5000
Berapa ukuran luas gudang di unit produksi, depot dan
setiap agen:
1. Jika setiap pallet produk memiliki dimensi yang sama dan
memerlukan 1.2x1.2 m2 area.
2. Barang akan diletakkan diatas rak dimana setiap raknya
terdiri atas 3 tingkat.
3. Lebar gang utama adalah 4 m dan gang lainnya 3,5 m
4. Cara penempatan barang dengan menggunakan random
policy