WAREHOUSING

WAREHOUSING

Andary A Munita Hanafiah

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Materi

• Function of Warehouse• Types of Warehouse• Structural Aspect• Functional Aspect• Warehouse Design• Warehouse Operation

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Function

Storage in Transit Inventory

Economic Service– Consolidation & Break Bulk - Spot Stocking – Assortment - Full Line Stocking– Postponement - Product Support– Stockpiling - Market Presence– Reverse Logistics

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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

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Consolidation

Plant A

Plant A

Plant A

ConsolidationWarehouse X Y Z

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Break-Bulk

Customer X

Customer Y

Customer Z

Break-BulkWarehouse

Plant A

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Assortment

Reconfigure freight as it flows from origin to destination

Cross Docking Mixing Assembly

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Cross-Dock

Plant A

Plant B

Plant C

DistributionWarehouse

Customer Y

Customer Z

Customer X

Combine inventory from multiple origins into an assortment for specific customer

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Mixing

Plant A

Plant B

Plant C

Transit MixingPoint

A B C

Product D

D

A

A

A B

B

B C

C

D

Customer W

Customer Y

Customer X

Customer Z

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Assembly

Vendor A

Vendor B

Vendor C

Lead SupplierWarehouse

Assy. Plant

Procure inventory from multiple Vendor to support manufacturing operations

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Postponement

Warehouse postpone commitment to final product configuration by completing final

packaging, labeling, and light manufacturing

Reduced Risk Lower Inventory

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Stockpiling

Accommodate seasonal production or demand

Buffer Stock

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Reverse Logistics

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

inventory

Control Regular

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Service

Establishing warehouse to service a specific market area

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

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Spot Stocking

• Spot Stocked 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

• Use temporarily Warehouse for Time Limited Period

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Full Line Stocking

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

manufacturers

• Use Permanent Warehouse for Unlimited Time Period

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Production Support

• Stock Inventory to Support Manufacturing Operation

• Support Warehouse Containing an Inventory of Processed Materials,

Components and Subassembly

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Market Presence

• Respond faster to customer needs

• Increase Market Share and Profitability

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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

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Storage Plan

Low Volume Low Volume

Receiving Dock

Shipping Dock

Receiving

High Volume

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Warehouse Ownership

Private Public Contract

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Warehouse Size

• Min = SSL + Q

• Max = SSL+T + Q

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Location and Site

Criteria

Services Operating Cost

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Faktor Lokasi

1. Pasar Dan Bahan Baku

Jasa Semen Fragile Kertas

Berat Agro Industri

SERVICES COST

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Faktor Lokasi

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

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Faktor Lokasi

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

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Tahapan Pemilihan Lokasi

Regional

MakroCommunity

MikroSite

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Metoda Pemilihan

• Gravitasi• BEP

• Transportasi• Point Rating• Simulasi

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Metoda Gravitasi

• Minimasi Ongkos Transportasi• Faktor Faktor Lain Tetap ( Sama Untuk Semua Pilihan Lokasi)• Menggunakan Koordinat Cartesian Sebagai Basis

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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

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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)

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Contoh Metoda Gravitasi

• Jx = (5x10x13) + ( 8x2x95) + ( 4x8x118) (5x10) + ( 8x2) + ( 4x8) = 91,3 KM

• JY = (5x10x22) + ( 8x2x84) + ( 4x8x41) (5x10) + ( 8x2) + ( 4x8) = 38,3 KM

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Metoda BEP

A

B

•Faktor Yang Lain Tetap ( Sama )•Fix Cost Dan Variable Cost Berbeda

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Metoda BEP

Total Cost Lokasi A = Total Cost Lokasi B

FA + Q. VA = FB + Q.VB

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

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Metoda Transportasi

• Multi Lokasi• Faktor Lain Sama Kecuali Ongkos Transport

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Metoda Point Rating

• Menggabungkan Faktor Tangible Dan Faktor Intangible

• Menggunakan Pendekatan Kwalitatif Dan Kwantitatif

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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

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Basic Warehouse Design

Receiving Area

Order Picking Area

Packaging or Unitizing Area

Staging Area

Bulk StorageArea

Rack StorageArea