Appendices
Appendix I
Table 1 Time studies executed by company A (numbers in seconds).
No picki n g bo x fr om pa llet scannin g ( 4 ti mes) ti
cking of sticking label (4th sc
an ) at ta ching shipping la bel close box with sticker tape bo x put box on the
conveyor total numb
er of seconds nee d ed per box 1 3 4 2 4 15 5 3 1 37 2 3 4 1 2 16 1 3 1 31 3 3 2 6 3 7 2 2 2 27 4 3 3 1 2 17 2 5 1 34 5 2 3 1 2 14 1 4 1 28 6 2 3 2 2 16 2 4 2 33 7 5 3 1 3 13 2 4 2 33 8 3 3 2 3 12 1 4 2 30 9 4 3 9 3 6 1 3 1 30 10 3 4 2 2 14 2 4 1 32 11 2 2 2 2 7 1 4 2 22 12 3 8 2 2 8 1 4 2 30 13 2 3 1 3 15 2 14 1 41 14 3 3 1 3 19 1 3 2 35 15 2 3 1 2 12 2 3 1 26 16 2 2 2 2 8 1 5 2 24 17 3 2 1 2 15 1 4 1 29 18 3 11 2 2 10 1 4 1 34 19 3 2 7 1 11 1 18 2 45 20 5 7 1 5 13 2 17 1 51 21 3 4 5 3 8 2 3 1 29 22 6 3 1 3 16 1 5 1 36 23 3 3 2 3 14 1 4 1 31 24 3 3 1 4 14 1 4 2 32 25 4 3 3 3 12 5 6 9 45 26 14 5 7 3 7 2 3 3 44 3,54 3,69 2,54 2,65 12,27 1,69 5,27 1,77 33,42 27 2 3 1 4 10 6 2 28 28 5 3 1 3 12 6 2 32 29 3 5 2 3 10 7 2 32 30 5 4 1 3 10 6 2 31 31 3 5 1 3 12 7 2 33 32 3 5 1 4 8 7 1 29 33 4 5 1 3 10 7 1 31 34 4 5 2 4 7 8 2 32 35 4 4 2 3 12 7 1 33 36 3 5 1 3 8 7 2 29 37 3 4 1 3 11 7 1 30 38 5 4 1 3 10 7 2 32
39 5 4 1 4 9 55 2 80 40 5 8 1 3 9 7 2 35 41 3 4 2 3 10 7 2 31 42 2 4 1 4 10 7 2 30 43 2 4 2 3 12 6 1 30 44 3 4 1 3 13 7 1 32 45 4 4 2 3 9 9 2 33 46 3 4 2 3 9 9 3 33 47 5 4 1 5 14 8 1 38 48 3 4 1 3 19 5 2 37 49 3 3 1 4 8 8 1 28 50 3 5 2 3 9 7 1 30 51 3 6 1 4 7 8 2 31 52 4 4 2 3 14 6 2 35 3,54 4,38 1,35 3,35 10,46 8,88 1,69 33,65 53 4 3 1 2 2 14 2 2 2 32 54 2 4 1 2 2 14 1 3 1 30 55 3 4 1 3 2 14 2 3 1 33 56 3 3 1 3 2 14 1 4 2 33 57 3 4 1 2 4 10 1 3 1 29 58 4 4 2 3 3 10 1 2 1 30 59 4 4 2 3 4 10 1 5 1 34 60 3 4 1 2 2 13 1 3 1 30 61 3 3 10 2 0 8 2 2 2 32 62 3 5 1 2 3 11 2 3 1 31 63 3 4 1 3 2 13 1 3 1 31 64 3 3 1 3 2 15 1 3 1 32 65 15 3 1 4 2 10 1 2 2 40 66 3 4 1 3 9 7 12 4 1 44 67 4 6 1 3 2 7 1 2 1 27 68 4 3 2 3 4 11 11 2 1 41 69 6 4 1 3 3 11 1 3 2 34 70 4 4 1 3 3 10 1 2 2 30 71 5 3 5 3 9 1 34 2 62 72 2 6 1 3 15 1 4 2 34 73 6 6 6 5 2 3 4 2 34 74 8 32 2 4 13 3 12 6 80 4,32 5,27 2,00 2,91 2,32 10,95 2,32 4,77 1,64 36,5 75 3 3 1 2 8 3 1 21 76 3 3 1 2 8 3 1 21 77 3 3 1 2 8 4 1 22 78 2 2 8 2 2 4 1 21 79 3 2 2 4 5 4 1 21 80 3 3 1 3 7 3 1 21 81 3 3 1 2 17 3 1 30 2,86 2,71 2,14 2,43 7,86 0,00 3,43 1,00 22,43
Figure 24 Activities timed of Company A 0,00 10,00 20,00 30,00 40,00 50,00 60,00 70,00
Packer 1 Packer 2 Packer 3 Packer 4 Average
Time (in sec.)
Put box on conveyor belt Tape box Close box with sticker Insert shipping label 4th scan Stick label Tick off Scan Pick box from pallet
Appendix II
Table 2 Time studies company B (numbers in seconds).
No Folding box tapin
g bo tto m scannin g in b ox
and confirmin g broch
u re s i n b ox tapin g
box sticking label sticking acceptanc e note put
aw
ay
box secon
ds
needed per box
1 6 4 6 3 5 2 7 33 2 4 3 7 4 8 2 6 34 3 4 9 7 4 5 2 6 37 4 5 6 8 3 5 6 7 40 5 4 5 7 5 5 3 7 36 6 6 5 5 5 4 5 5 35 7 4 4 5 4 6 5 14 42 8 3 6 8 3 5 5 6 36 4,50 5,25 6,63 3,88 5,38 3,75 7,25 36,63 9 3 6 6 3 6 3 6 33 10 5 5 6 3 5 7 6 37 11 5 4 8 5 5 3 7 37 12 4 5 6 4 5 6 5 35 13 4 9 5 4 5 3 7 37 14 5 5 5 4 5 5 4 33 15 4 5 6 3 6 3 6 33 16 4 4 6 4 5 3 8 34 17 4 6 5 5 6 6 3 35 18 5 5 4 4 6 3 5 32 19 4 7 5 4 5 4 3 32 20 4 6 6 3 6 2 8 35 21 4 4 6 4 6 2 5 31 22 4 6 6 4 5 2 6 33 7 23 4 6 5 4 5 3 6 33 24 4 5 6 4 5 2 6 32 25 4 5 6 3 6 3 4 31 26 4 6 6 7 5 6 6 40 27 4 5 5 4 5 2 3 28 28 5 5 5 4 6 4 4 33 29 5 6 5 5 5 5 6 37 30 4 5 5 4 5 3 5 31 31 5 4 6 4 5 3 3 30 32 5 6 5 5 5 4 6 36 33 5 5 6 3 7 2 5 33 34 76 35 4 4 4 5 5 3 6 31 36 6 5 5 3 6 2 5 32 10 37 4 4 7 3 5 3 4 30 38 4 5 6 3 5 3 5 31 39 5 4 5 3 5 4 3 29
0,00 10,00 20,00 30,00 40,00 50,00 60,00 70,00
Packer 1 Packer 2 Packer 3 Packer 4 Average Time (in sec.)
Put box on pallet Stick acceptance note Stick label Tape box Put brochures in box Put article in box Scan Tape bottom Fold box
Figure 25 Activities timed of Company B
Packer 4 packs products which need an extra acceptance note and brochures. This asks a lot more time to pack. The average includes these four packers, only the two extra activities of the fourth packer are not taken into account. The fifth packer was distracted a lot during his activities and is not included in the graph.
40 5 4 6 5 5 3 5 33 41 5 5 5 3 4 5 4 31 4,41 5,19 5,56 3,94 5,31 3,50 5,16 33,06 42 4 6 5 4 6 3 3 31 43 4 4 4 5 5 3 5 30 44 4 5 5 4 4 3 7 32 45 4 5 3 4 5 3 7 31 46 4 6 4 4 5 2 6 31 47 5 6 5 4 6 2 5 33 48 4 6 5 4 7 5 5 36 49 4 6 4 5 5 3 7 34 50 4 7 5 4 6 2 9 37 51 4 6 5 4 6 3 6 34 52 4 7 7 3 6 3 5 35 4,43 5,20 5,78 3,93 5,33 3,55 5,58 33,78 53 5 5 5 2 7 4 2 21 4 55 54 5 6 6 2 6 4 3 21 5 58 55 7 5 5 1 9 7 3 22 4 63 56 5 5 4 4 6 4 3 25 3 59 57 5 5 5 4 7 4 3 26 5 64 5,40 5,20 5,00 2,60 7,00 4,60 2,80 23,00 4,20 59,80 58 7 7 5 5 4 3 8 39 59 6 6 4 10 6 3 6 41 60 5 5 9 6 7 9 5 46 61 12 10 4 4 4 20 35 together 72 62 5 8 9 6 10 9 together 64 63 10 8 7 8 6 4 11 54 64 8 6 6 5 8 3 20 together 46 65 9 8 11 9 8 27 together 82 66 7 13 16 5 5 5 4 55 7,67 7,89 7,89 6,44 6,44 9,22 9,89 55,44
Appendix III
Table 3 Average seconds of activities of company B
Fold box Tape bottom Scan Put television in box Put brochures in box Tape box Stick label Stick acceptance note Put box on pallet Total 4,50 5,25 6,63 3,88 5,38 3,75 7,25 36,63 4,41 5,19 5,56 3,94 5,31 3,50 5,16 33,06 4,43 5,20 5,78 3,93 5,33 3,55 5,58 33,78 5,40 5,20 5,00 2,60 (7,00) 4,60 2,80 (23,00) 4,20 29,80 4,68 5,21 5,74 3,58 (7,00) 5,15 3,40 (23,00) 5,55 33,32
Table 4 Average seconds of activities of company A
Picking box from
pallet Scan (4 times) Tick of Stick label (4
th scan) Insert shipping label Close box with
sticker Tape box
Put box on conveyor total number of seconds needed per box 3,54 3,69 2,54 2,65 12,27 1,69 5,27 1,77 33,42 3,54 4,38 1,35 3,35 10,46 8,88 1,69 33,65 4,32 5,27 2,00 2,91 2,32 10,95 2,32 4,77 1,64 36,50 2,86 2,71 2,14 2,43 7,86 3,43 1,00 22,43 3,56 4,02 2,01 2,83 2,32 10,39 2,01 5,59 1,52 31,50
First impressions of companies A and B
Company A:
Some use a sticker to tape easier and some make their 4th scan (commando ‘box ready’) later on in the
process.
Company B:
As shown in the figure above, packer 4 is the fastest and does not need to sticker. The shipping label is coming faster than the other employees and it does not depend on the work-station (employee 1 and 4 were active on the same work station). Comparing the other three means the activity ‘closing box with sticker’ takes still less seconds than packer 2 closing the box without the sticker activity. The slowest packer uses 36 seconds to pack one box. This comes to 750 boxes per packer per day equals a maximum capacity of 5250 boxes a day.
Appendix IV
Appendix V
Figure 27 Input Class “order profile”
Figure 29 Input Class “velocity EPT”
Figure 31 Output Class “labour utilization EPT”
Appendix VI
Figure 33 Conventional order picking
Figure 34 Compact Pick System VanderLande B.V.
Appendix VII
Table 5 Profile Company I
Data Customer
SKUs 2.241
Lines/order 40
units/line 1,1
Pickface 2.850 Locations frequent assortment update operational /day 12 H
Peak handling 150 %
Peak handling More people in 12 h or extra shift
# carriers 4 carriers are responsible for fine sorting
growth scenario 25% from 20 Mio to 25 Mio items per year (=25% volume growth) Even order profile during the day without peaks
shipping carton1 465 300 300 Mm for zone 01 products
shipping carton2 950 400 200 Mm for zone 13 products
Vshipping carton1 41,85 l bruto
Vshipping carton2 76 l bruto
Assumptions Vanderlande Industries
SKU growth 10%
SKUs future 2.465
volume (m3) growth linear to item growth occupancy carton 65%
Vshipping carton1 27,2 l netto
Vshipping carton2 49,4 l netto
Vstorage carton 50 l netto
Data information
AVERAGE DAY PEAK DAY
zone 01 zone 13 Total zone 01 zone 13 total
SKUs 1.911 330 2.241 1.911 330 2.241 order lines/day 67.306 9.166 76.472 100.959 13.749 114.708 units/day 75.546 9.374 84.920 113.319 14.061 127.380 m3/day 134 64 198 201 96 297 pallets/day 176 73 249 264 110 374 Results
AVERAGE PEAK (12 h operational)
zone 01 zone 13 Total zone 01 zone 13 total
orders/day 1.683 229 1.912 2.524 344 2.868 units/line 1,12 1,02 1,11 liter/line 1,99 6,98 2,59 liter/order 79,64 279,29 103,57 order lines/h 5.609 764 6.373 8.413 1.146 9.559 units/h 6.296 781 7.077 9.443 1.172 10.615 m3/h 11 5 17 17 8 25 pallets/h 15 6 21 22 9 31
orders/h 140 19 159 210 29 239 # carton1/order 2,9 0 # carton2/order 0 5,7 # carton1/h 411 0 411 616 0 616 # carton2/h 0 108 108 0 162 162 Total cartons/h 518 778 Lines/storage carton 19,3 Pareto % SKUs 30 Lines 75 units 76 volume 58 pallets 55
Three notes according to the calculations above of VanderLande B.V. can be made:
- The number of lines per order is averaged by 40 for both zones. In stead zone-13-items has fewer lines than zone-1-items, it is not possible to make one number for these two types.
- Carton type 2 should be transported through zone 1 after being filled with zone-13-items and still having space for zone-1-zone-13-items.
- ZPS uses a machine to erect the cartons automatically. This machine is independent of the system and can be used in all three scenarios with a saving of 2 employees a year.
Table 6 FTE 2006 of company I Pick pack operational 12 h/day operational 5 days/week operational 52 weeks/a effective hours/FTE/year 1.450 h/a
Cost FTE 32.000 €/a carton 1 carton 2
total shipping
cartons/h 518 411 108
ods concept 75% of order lines with ods, rest manual picking
performance manual ods Zps
carton erection
manual 200 200 200 zps: erecting carton 1 automatically
replenishment
(cartons/h) 200
picking1 (lines/h) 100 5.793 150 ods: batch pick, zps: pallet flow rack
picking2 (lines/h) 400 350
ods: ods pick FM, zps: carton flow rack
picking3 (lines/h) 150 150 ods: pre pick manual MM/SM, zps: shelving
picking3 (lines/h) 300 ods: odsverdelen MM/SM
packing
(cartons/h) 100 100 100 ods and zps: packing carton 1 automatically sorting/palletising
(cartons/h) in packing 400 400
sorting ods and zps automatically, rest: manually put away on 4 pallets (4 carriers)
concept manual ods Zps
orderlines/h 6.373 4.780 643 ods: batch pick, zps: pallet flow rack
4.780 4.858 ods: ods pick FM, zps: carton flow rack
1.593 872 ods: prepick manual en odsverdelen MM/SM, zps: shelving
manh/h manual ods Zps
replenishment 1,3
carton erection 2,6 2,6 0,5 zps: erecting carton 1 automatically
picking1 63,7 0,8 4,3
picking2 11,9 13,9
picking3 10,6 5,8
picking4 5,3
sorting/palletising 1,3 1,3
ods and zps: sorting automatically, manual process: manually put away on 4 pallets (4 carriers)
totaal 71,5 33,7 28,2
manh/a manual ods Zps
223.102 105.066 87.839
Fte 154 72 61
fte cost/a 4.923.624 2.318.699 1.938.508 3 years 14.770.871 6.956.098 5.815.525 5 years 24.618.119 11.593.496 9.692.542
invest (Mio euro) 4 3,8 rough estimate
difference with manual process
ods Zps
Fte 81 93
fte cost/a 2.604.925 2.985.115
3 years 7.814.774 8.955.346
Table 7 FTE Future of company I pick pack operational 12 h/day operational 5 days/week operational 52 weeks/a effective hours/FTE/year 1.450 h/a
Cost FTE 32.000 €/a carton 1 carton 2
total shipping
cartons/h 648 513 135
ods concept 75% of order lines with ods, rest manual picking
performance manual ods Zps
carton erection
manual 200 200 200 zps: erecting carton 1 automatically
replenishment
(cartons/h) 200
picking1 (lines/h) 100 5.793 150 ods: batch pick, zps: pallet flow rack picking2 (lines/h) 400 350 ods: ods pick FM, zps: carton flow rack
picking3 (lines/h) 150 150
ods: pre pick manual MM/SM, zps: shelving
picking3 (lines/h) 300 ods: odsverdelen MM/SM
packing
(cartons/h) 100 100 100 ods and zps: packing carton 1 automatically sorting/palletising
(cartons/h) in packing 400 400
ods and zps: sorting automatically, rest: manually put away on 4 pallets (4 carriers)
concept manual ods Zps
orderlines/h 7.966 5.975 803 ods: batch pick, zps: pallet flow rack
5.975 6.072 ods: ods pick FM, zps: carton flow rack
1.992 1.090
ods: prepick manual en odsverdelen MM/SM, zps: shelving
manh/h manual ods Zps
replenishment 1,6
carton erection 3,2 3,2 0,7 zps: erecting carton 1 automatically
picking1 79,7 1,0 5,4
picking2 14,9 17,3
picking3 13,3 7,3
picking4 6,6
packing 6,5 1,3 1,3
ods and zps: packing carton 1 automatically
manual process: manually put away on 4 pallets (4 carriers)
totaal 89,4 42,1 35,2
manh/a manual ods Zps
278.869 131.329 109.778
Fte 192 91 76
fte cost/a 6.154.358 2.898.296 2.422.684
3 years 18.463.073 8.694.889 7.268.052
5 years 30.771.788 14.491.482 12.113.420
difference with manual process
Ods Zps
Fte 102 117
fte cost/a 3.256.061 3.731.674
3 years 9.768.183 11.195.021
