Title: Ferrero Belgium optimizes its warehouse thanks to the Warehouse Management System of Generix Group
1- Ferrero Belgium optimizes its warehouse thanks to
the Warehouse Management System of Generix Group
2Introduction
- SV Management Consultants
- Deliver state-of-the-art advice in Supply Chain
Strategy and Performance and in Supply Chain
Process Excellence. - Ferrero
- Distribution center in Ternat
- /- 600 references
- 4.200 pallet locations
- 3.600 bulk locations
- 620 pick locations
- 12 operators
- WMS
3Project goal
- Define the future warehouse organization (Ternat)
- Layout, Storage capacity, Optimal Material flow
- Roles Responsibilities, KPIs
- Benchmarking (efficiency cost)
- Provide a sustainable solution towards future
volumes profile changes
4Project Approach
- Interviews
- Observations
- Data analysis
Project Timing
- Analysis phase 2008
- Programming phase Started December 2008
- Testing phase February 2009
- Go live May 2009
5Prioritizing improvement actions
IMPACT
MOQ per OL
12
Split case picking- Pallet transfer to dock
Balance Case-Pallet pick
Balance Inbound flows based on outbound flows
Completed
15
10
11
OR
1st priority actions
high
Related actions
Scrapping on quintale base
15 000
CSC actions
Pallet volume calculation
Planning actions
21
1 step receiving
16
7
medium
Out of scope
Floor storage
Balancing inbound Production plants
6-9
1
5 000
3
14
20
4
13
low
2
5
17
EFFORT
high
low
medium
6Selected actions
- Split case picking and pallet transfer to dock
- One step receiving One step loading
- Floor storage
71. Split case picking pallet transfer to dock
- AS IS process
- Order picker prepares picking pallet
- Order picker wraps picking pallet
- Order picker brings pallet to dock
- TO BE process
- Order picker prepares picking pallet
- Order picker wraps picking pallet
- Order picker brings pallet to dock X1, X2, X3
- OR
- Order picker brings pallet to buffer zone picking
- Servant brings pallet to dock
Goal Order pickers do order picking and bring
pallets to buffer zone OR bring pallets to docks
close to order picking zone Gain Use of empty
rides servants after replenishment process (from
bulk to picking zone)
81. Split case picking pallet transfer to dock
Stock PLV
10,4 m
Detail/ SPE
5,9 m
Picking zone
10,4 m
30 m
Floor storage
5,7 m
Empty pallets
18,4 m
15,8 m
14 m
Floor storage
Buffer Picking
4,8 m
4,8 m
2,4 m
9 m
AS IS flow
92. One step receiving one step loading
- AS IS process receiving
- Unloading truck put pallets on dock
- Control of pallets
- Scan pallets
- Bring pallets to bulk drop zone in
- AS IS process loading
- Bring pallets from bulk drop zone out to dock
- Control of pallets
- Scan pallet
- Load pallets into truck
- TO BE process receiving
- Scan pallet in truck
- Bring pallet to bulk drop zone in
- TO BE process loading
- Scan pallet at bulk drop zone out
- Load pallet into truck
Goal Avoid putting pallets on docks during put
away process especially when unloading full truck
of 1 product Gain No control action Put pallets
immediately in front of bulk zone
10 2. One step receiving one step loading
Stock PLV
10,4 m
Detail/ SPE
5,9 m
Picking zone
10,4 m
30 m
Floor storage
5,7 m
Empty pallets
18,4 m
15,8 m
14 m
Floor storage
Buffer Picking
4,8 m
4,8 m
2,4 m
9 m
AS IS flow
2-step
1-step
113. Floor storage
- AS IS process
- Scan pallet
- Put pallet from dock into bulk drop zone in
- Put pallet in bulk
- Get pallet out of bulk
- Scan pallet
- Bring pallet from bulk drop zone out to dock
- TO BE process
- Scan pallet
- Put pallets from dock (or from truck) into floor
storage zone - Get pallet out of floor storage zone
- Bring pallet to dock
Goal Avoid putting pallets in bulk which will we
delivered to customers within a few days Gain
Pallets movements in and out of bulk
123. Floor storage
Stock PLV
10,4 m
Detail/ SPE
5,9 m
Picking zone
10,4 m
30 m
Floor storage
5,7 m
Empty pallets
18,4 m
15,8 m
14 m
Floor storage
Buffer Picking
4,8 m
4,8 m
2,4 m
9 m
AS IS flow
13Improvement actions and their impact
14Challenges Conclusions
- Support needed of total Supply Chain for
realization of improvement actions - One step receiving loading requires perfect
quality SSCC labels - Need for cooperation of production plants on
- Quality SSCC labels
- Number of SSCC labels per pallet
- Importance of testing phase
- Communication/involvement of operators
15- Thank you for your attention!
- Welcome at stand 72 for coffee and