WAREHOUSING Andary A Munita Hanafiah Materi Function of

WAREHOUSING Andary A Munita Hanafiah

Materi • • • Function of Warehouse Types of Warehouse Structural Aspect Functional Aspect Warehouse Design Warehouse Operation 2

Function Storage in Transit Inventory Economic – – – Consolidation & Break Bulk Assortment Postponement Stockpiling Reverse Logistics Service - Spot Stocking - Full Line Stocking - Product Support - Market Presence 3

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 4

Consolidation Plant A Consolidation Warehouse X Y Z Plant A 5

Break-Bulk Customer X Plant A Break-Bulk Warehouse Customer Y Customer Z 6

Assortment Reconfigure freight as it flows from origin to destination Cross Docking Mixing Assembly 7

Cross-Dock Combine inventory from multiple origins into an assortment for specific customer Plant A Plant B Plant C Customer X Distribution Warehouse Customer Y Customer Z 8

Mixing Customer W A Plant A B C D Customer X A Plant B Transit Mixing Point Product D Plant C B C D Customer Y A B C Customer Z A B 9

Assembly Procure inventory from multiple Vendor to support manufacturing operations Vendor A Vendor B Lead Supplier Warehouse Assy. Plant 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 • 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 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 – Receiving – In Storage Handling – Shipping Storage - Active - Extended 19

Storage Plan Receiving Dock Low Volume High Volume Low Volume Shipping Dock 20

Warehouse Ownership Private Public Contract 21

Warehouse Size • Min = SSL + Q • Max = SSL+T + Q 22

Location and Site Criteria Services Operating Cost 23

Faktor Lokasi 1. Pasar Dan Bahan Baku Jasa Semen Fragile Kertas Berat Agro Industri SERVICES COST 24

Faktor Lokasi 2. Tangible. Transportasi. Tenaga Kerja. Energi. Tanah. Insentif . Utilitas. Biaya Konstruksi. Pajak. Bahan Penolong. Dll 25

Faktor Lokasi 3. Intangible – Iklim – Peraturan – Stabilitas Politik – Kemudahan Ekspansi – Budaya – Polusi – Dll 26

Tahapan Pemilihan Lokasi Regional Makro Community Mikro Site 27

Metoda Pemilihan Gravitasi • BEP • Transportasi • Point Rating • Simulasi • 28

Metoda Gravitasi • Minimasi Ongkos Transportasi • Faktor Lain Tetap ( Sama Untuk Semua Pilihan Lokasi) • Menggunakan Koordinat Cartesian Sebagai Basis 29

Formula Metoda Gravitasi J = Ti B i Ji / Ti B i 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 30

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) 31

Contoh Metoda Gravitasi • Jx = (5 x 10 x 13) + ( 8 x 2 x 95) + ( 4 x 8 x 118) (5 x 10) + ( 8 x 2) + ( 4 x 8) = 91, 3 KM • JY = (5 x 10 x 22) + ( 8 x 2 x 84) + ( 4 x 8 x 41) (5 x 10) + ( 8 x 2) + ( 4 x 8) = 38, 3 KM 32

Metoda BEP • Faktor Yang Lain Tetap ( Sama ) • Fix Cost Dan Variable Cost Berbeda A B 33

Metoda BEP Total Cost Lokasi A = Total Cost Lokasi B FA + Q. VA = FB + Q. VB Q = (FA - FB )/ (VB - VA ) 34

Metoda Transportasi • Multi Lokasi • Faktor Lain Sama Kecuali Ongkos Transport 35

Metoda Point Rating • Menggabungkan Faktor Tangible Dan Faktor Intangible • Menggunakan Pendekatan Kwalitatif Dan Kwantitatif 36

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 37

Basic Warehouse Design Receiving Area Bulk Storage Area Rack Storage Area Order Picking Area Packaging or Unitizing Area Staging Area 38