Warehousing Unmul

Warehousing
Warehousing
Muriani Emelda Isharyani
Function
Storage in Transit Inventory
Economic
Consolidation & Break Bulk
Assortment
Stocking
Postponement
Stockpiling
Presence
Reverse Logistics
Warehousing
Service
- Spot Stocking
- Full Line
- Product Support
- Market
Consolidation
Plant A
Plant B
Consolidation
Warehouse
Plant C
Warehousing
X Y Z
Consolidation
Warehousing
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
Warehousing
Break-Bulk
Customer X
Plant A
Break-Bulk
Warehouse
Customer Y
Customer Z
Warehousing
Break-Bulk
Warehousing
Assortment
Reconfigure freight as it flows from
origin to destination
Cross Docking
Assembly
Mixing
Warehousing
Cross-Dock
Combine inventory from multiple origins into an
assortment for specific customer
Plant A
Plant B
Customer X
Distribution
Warehouse
Plant C
Customer Y
Customer Z
Warehousing
Cross-Dock
Enables receipt of full shipments from a number of suppliers, generally
manufacturers, & direct distribution to different customers without storage
Warehousing
Mixing
Customer W
A B C D
Plant A
Customer X
A B C D
Plant B
Transit Mixing
Point
Customer Y
Product D
A B C
Customer Z
Plant C
A B
Warehousing
Assembly
Procure inventory from multiple Vendor to
support manufacturing operations
Vendor A
Vendor B
Lead Supplier
Warehouse
Vendor C
Warehousing
Assy. Plant
Postponement
Accommodate seasonal
production or demand
For example, lawn
furniture and toys are
typically produced yearround but are sold only
during a very short
marketing period
Warehousing
Stockpiling
To accommodate seasonal
production or demand
For example, agricultural
products are harvested at
specific times, with
subsequent consumption
occuring throughout the
year
Warehousing
Reverse Logistics
Processing
Facilitate the
reverse flow
of product
that did not
sell or to
accommoda
te recalls
Facilitate the
reverse flow
of product
following its
useful life
then update
for sale at a
discounted
price
Use
coordination &
reverse flow
to position &
resell product
when the
original user
no longer
needs it
Returns product
following its
useful life with
the objective of
decomposing it
to its
component
materials so
that they can be
effectively
When
material
cant be
effectively
reused, it
may
dispose of it
in the
appropriate
landfill
Service Benefits
May increase cost but should also increase
market sales, revenue and potentially gross

margin
can provide service as a result
Warehouses
Spot-Stocking: stocking of products in strategically located
of:warehouses during demand sensitive period
Ex: agricultural implements are spot stocked during the growing
season
Full line stocking: stocking product inventory combinations from
different manufacturers to provide one-stop shopping capability
for customer. This will improve service by reducing the number
of suppliers that a customer must logistically deal with
Value-added services: any work that creates a greater value for
customers.
Ex: vegetables can be processed and canned in brights at the
Warehousing
processing plants. Once
a specific customer order is received,
the warehouse can complete labeling and finalize packaging.
Flow of Goods in
Warehouse
Receiving
Receiving
Holding
Holding
Picking
Picking
Shipping
Shipping
Warehousing
Flow of Goods in
Warehouse
Receiving
Receiving
Receiving
Holding
Holding
Holding
Picking
Picking
Picking
BatchForming
Forming
Batch
Packaging
Packaging
Shipping
Shipping
Warehousing
Sentralisasi fungsi
penerimaan dan
pengiriman
Keuntungan
Memaksimalkan penggunaan peralatan
memaksimalkan penggunaan personal
efisiensi ruangan
pengurangan biaya fasilitas
Kendala
jika pengaturan aliran material tidak tertib
dapat menimbulakan kesemerawutan dan
kemacetan.
Warehousing
Fungsi Penerimaan
(Receiving)
Menerima seluruh material yang datang dari
pemasok eksternal maupun internal

memeriksa material/barang yang datang
memeriksa dokumen yang menyertai material
tersebut
mencatat faktur penerimaan
mencatat jika ada kunatitas/kualitas yang barang
yang tidak sesuai
membuat laporan penerimaan barang
mengirim ke tempat penyimpanan
Warehousing
Fungsi Departemen
Penerimaan
Area alat angkut
dockdoor
dockboard
area pallet atau container
area penempatan produk
kantor
aisle
Warehousing
Fungsi Pengiriman
(Shipping)
Melakukan pengepakan barang yang
akan dikirim
pemberian alamat pada karton
pembungkus atau kontainer
melakukan penimbangan kontainer
melakukan penempatan trailer
loading dan distribusi
Warehousing
Penyimpanan (Storage)
Jenis gudang
bahan baku/suku cadang/ WIP
barang jadi
barang untuk keperluan administrasi
peralatan
Warehousing
Storage Media
Physical Characteristics of Goods
in Stock
Solid Goods: Stack, Rack, Drawers
Number of items of each product

in a customer order
Warehousing
Selecting The
Storage/Retrieval
Physical Characteristics of goods
Packaging at the arrival
Composition of out going lots
Stack
Rack
Warehousing
Drawers
Warehousing
Warehouse Decisions
Pemilihan Lokasi
Desain
Product-Mix Analysis
Expansion
Material Handling
Layout
Sizing
Warehousing
Location and Site

Criteria
Services
Cost
Warehousing
Operating
Faktor Lokasi
1. Pasar Dan Bahan Baku
Jasa
Semen
Fragile
Kertas
Berat
Agro Industri
SERVICES
Warehousing
COST
Faktor Lokasi
2. Tangible
. Transportasi
.
.
.
.
Tenaga Kerja
Energi
Tanah
Insentif
. Utilitas
. Biaya Konstruksi
. Pajak
. Bahan Penolong
. Dll
Warehousing
Faktor Lokasi
3. Intangible
Iklim
Peraturan
Stabilitas Politik
Kemudahan Ekspansi
Budaya
Polusi
Dll
Warehousing
Tahapan Pemilihan Lokasi

Regional
Makro
Community
Mikro
Site
Warehousing
Metoda Pemilihan
Gravitasi
BEP
Transportasi
Point Rating
Simulasi
Warehousing
Metoda Gravitasi
Minimasi Ongkos Transportasi
Faktor Faktor Lain Tetap
( Sama Untuk Semua Pilihan Lokasi)
Menggunakan Koordinat Cartesian
Sebagai Basis
Warehousing
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
Warehousing
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)
Warehousing
Contoh Metoda Gravitasi

Jx = (5x10x13) + ( 8x2x95) + ( 4x8x118)
(5x10) + ( 8x2) + ( 4x8)
= 91,3 KM
JY = (5x10x22) + ( 8x2x84) + ( 4x8x41)

(5x10) + ( 8x2) + ( 4x8)
= 38,3 KM
Warehousing
Metoda BEP
Faktor Yang Lain Tetap ( Sama )
Fix Cost Dan Variable Cost Berbeda
A
B
Warehousing
Metoda BEP
Total Cost Lokasi A = Total Cost
Lokasi B
FA + Q. VA = FB + Q.VB
Q = (FA - FB )/ (VB - VA )
Warehousing
Metoda Transportasi
Multi Lokasi
Faktor Lain Sama Kecuali Ongkos
Transport
Warehousing
Metoda Point Rating

Menggabungkan Faktor Tangible
Dan Faktor Intangible
Menggunakan Pendekatan
Kwalitatif Dan Kwantitatif
Warehousing
Prosedur
Identifikasikan Faktor Yang Relevan

Tentukan Bobot Setiap Faktor
Tentukan Rating Faktor Pada Setiap
Lokasi
Htung Bobot Score Pada Setiap Lokasi
Untuk Setiap Faktor
Jumlahkan Bobot Skor Pada Setiap
Lokasi
Pilih Lokasi Yang Memiliki Skor
Tertinggi
Warehousing
Contoh
Banten
Faktor
O.Ops
B.Baku
T.Kerja
B.Hidup
Lingkung.
Pasar
Bobot
0.33
0.25
0.20
0.05
0.02
0.15
1.00
Rat.
Bobot
Skor
Skor
50
70
55
80
60
80
16.5
17.5
11.0
4.0
1.2
12.0
62.60
Bandung
Rat.
Skor
40
80
70
70
60
90
Warehousing
Bobot
Skor
13.2
20.0
14.0
3.5
1.2
13.5
65.40
Surabaya
Rat.
Skor
35
75
60
40
60
85
Bobot
Skor
11.35
18.75
12.00
2.00
1.20
12.75
55.25
Warehouse Design
Criteria
Services
Warehousing
Cost
Warehouse Cost
Receiving Cost
Holding Inventory Cost
Retrieving Cost
Assembling to customer order
Cost
Shipping Cost
Warehousing
Factors To Be Determined
Number of floors to include in
the facility
A cube utilization plan
Product flow
Warehousing
Warehouse Design
1. Determining the capacity: length,
2.
3.
4.
width and height

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)
Selecting the storage medium
Selecting the storage/retrieval
transport mechanism
Warehousing
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
truck
Warehousing
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
Warehousing
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
Warehousing
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
Warehousing
Sizing of Storage Area

Dedicated Storage policy:
n
MD
MD = j=1
max Ij(t)
: Number of required storage location
Ij(t) : Inventory level of item j at time t
: Number of item
Random Storage policy:

Mr = max Ij(t) MD
Warehousing
Example of Storage
Area
Product
P
Q
Dedicated
Lot
Safety Stock
500
100
200
80
Storage policy:
MD = max Ij(t)
= 600 +280 = 880
Random Storage policy:
Mr = max Ij(t) MD
= 600 + 180 = 780
Warehousing
Length and Width of

Storage
Length:
Width :
Lx = ( ax + wx )nx
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
Warehousing
A Traditional Storage Zone

Wx
Wy
Warehousing
Model of Sizing The Storage Zone

Minimize:
1 nx y n y wy
x wx
2 v
2v
Subject to:
nxnynz m
nxny 0,integer
Warehousing
Determining nx and ny
Number of Storage Location Along Y
Direction
n'y
2m x 12 wx
ynz
Number of Storage Location Along X

Direction
n'x
m y
2nz x 12 wx
nx n'x
and
ny n'y
Warehousing
Example
Berapa ukuran luas gudang untuk menampung produk P
dan Q diatas jika:
1. Jika setiap pallet produk P dan Q 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 pemenpatan barang dengan menggunakan
random policy
Warehousing
Example
780 1.05
n' x
6
.
05
2 4 1.05 32.5
n' y
3.5
2 780 1.05 2
1.05 4
Warehousing
32.25
Example
nx = 6 and ny = 33
Length:
Lx = ( ax + wx )nx
= ( 1.05 +(3.5/2))x6
= 16.8 m
Width :
Ly = ( ay ny + wy )
= [(1.05x33)+4]
= 38.65 m
Warehousing
Tugas
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
Warehousing
Data Pada Agen

Agen
j
1
2
3
4
5
6
7
8
9
10
Aj
Rp/Psn
50000
40000
30000
60000
75000
65000
70000
60000
55000
70000
Hj
Rp/unit/thn
4000
6000
8000
10000
12000
8000
10000
8000
12000
8000
Bj
Rp/unit
50000
50000
35000
40000
40000
30000
40000
45000
50000
40000
Dj
unit/thn
5000
4000
4500
5000
6000
5500
6000
5000
4000
5000
Sj
unit/thn
500
400
500
500
600
550
600
500
400
500
Warehousing
Ldj
thn
0.05
0.03
0.10
0.10
0.05
0.05
0.10
0.05
0.05
0.03
Cdj
Rp/unit
9500
8000
9000
8000
6000
6000
9000
6000
6000
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
Warehousing

Warehousing Unmul

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Warehousing

Consolidation & Break Bulk

using warehouse capability to

May increase cost but should also increase

market sales, revenue and potentially gross

Menerima seluruh material yang datang dari

pemasok eksternal maupun internal

Solid Goods: Stack, Rack, Drawers

Number of items of each product

Location and Site

Tahapan Pemilihan Lokasi

Ti : Biaya Transport Dari Tiap Titik i Ke Lokasi

Bi : Berat Yang Diangkut Dari / Ke Lokasi i

Contoh Metoda Gravitasi

A ( 13, 22) ; B (95,84) ; C(118,41)

Contoh Metoda Gravitasi

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

Metoda Point Rating

Identifikasikan Faktor Yang Relevan

width and height

ND : Number of Dock Truck

d : Daily demand from all order

Number of dock truck:

2. Random Storage policy:

Current warehouse occupation

Allow a higher utilization of space but requires:

Each item be automatically identified

Sizing of Storage Area

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

Random Storage policy:

Random Storage policy:

Length and Width of

A Traditional Storage Zone

Model of Sizing The Storage Zone

Number of Storage Location Along X

produksi, satu depot dan 10 agen. Unit

Data Pada Agen

Berapa ukuran luas gudang di unit produksi, depot dan

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