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Advanced methodologies in productionCAD & Computer Integrated Manufacturing

Split case order fulfillment methods

Communication of picking directives

Order picking & packing economics

Capital costs for online storages

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CAD

CAD means Computer Aided Design.

CAD is the use of computer technology to aid in the design andparticularly the drafting (technical drawing) and engineering drawing)of a part or product.

It uses 2 or 3 dimensional images which can be sent via internet orintranet.

It can create the volume, weight of components, CG, deflection underestimated load, design parameters.

It reduces time required to make a design or modify a product.

Laborious mechanical drawing or complicated calculations can bedone very easily.

Analysts use CAD to store, retrieve and classify data of various parts.

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Computer integrated manufacturing

It is the complete automation of a manufacturing plant, with allprocesses functioning under computer control & digital information.

It includes functions like production, design and managementfunction.

Three main computer aid in CIM are :

- Computer aid to production function ( automated flow of materials )

- Computer aid to the design function ( automated f low of technologicalinformation )

- Computer aid to the management function ( automated f low of

management information ) It increases the customer satisfaction as response time decreases.

It enhances throughput & better utilization of space.

Eg. Barcoded labels, RFID tags.

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CIM includes processes like engineering design, production planning,shop control, order processing, material control, distribution.

It helps in rapid production and reduces indirect costs.

It helps in avoiding accumulation of materials resulting in output andbetter utilization of space.

At present 40 % of manufacturing companies are now using CIMtechnology in different forms.

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Split case order fulfillment method

It is used when the customer requires different merchandise indifferent quantities.

The cases are splited, pieces are picked & repacked according torequirement of customer.

It improves identification, pick up & repacking of materials andreduces monotony of workers.

It includes

- Order picking methods

- Sorting and routing

- Order packing methods

- Classification schemes

- Choice of optimal fulfillment strategies

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Order picking method

(1) Order extent : It represents the numbers of order simultaneouslypicked by the picker in an assignment.

- It involves 2 methods:a. Discrete order picking where a single order is selected at a time.

- A single worker picks only one order and collects all items to fulfillthe customers need.

- Advantages includes- Simple & reliable method- Best suited for smaller organisation- Minimises confusion, maximises cycle time

b. Batch order picking where many order of different material are

put together & selected for a pick.- The picker picks many items for multiple orders which are to be

separated into different cartoons.- It is best suited for a big pack distance ie. Make one trip for 10 orders

instead of 10 trips for 10 orders.

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(2) Coverage extent :

- It represents the physical area travelled by picker in

selecting the material in the picking system from a zone.

- I tour picking the entire picking area is considered forpicking merchandise.

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Order packing methods Pack immediate :

- Here they are packed as they are picked

- Applicable to where used by customer directly & tools & packaging

material are available with the picker

Assemble & pack :

- The orders are assembled together in a dedicated area equipped forpacking.

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Classification schemes It involves coding of various methods of split picking and packing.

1stletter : Dfor discrete order picking (or)

Bfor batch order picking

2ndletter : Zfor zone picking (or)

Tfor tour picking

3rdletter : Pack Immediate (0r)Assemble and pack

For ex. DZAmeans discrete order picking system where picker covers theentire zone picking area ad then assembles and packs the order as it is

selected.

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1stletter : Bs batch order picking - Sort immediate

Bm batch order picking - Merge & sort

2ndletter : Zr zone picking with Routing

Zc zone picking with Chaining

Zp zone picking in Parallel

For ex. BsZcA means batch order picking in chaining multiple zones withimmediate sorting and assemble.

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Choice of optimal fulfillment strategies

It depends on order characteristics & category of distribution

General order categories are:

1) Wholesale distribution ( large nos of pieces of a few item )

2) Retail distribution ( large nos of pieces for a large nos. of items )

3) Direct marketing ( small quantities )

4)Consumer distribution ( small quantities of different items usuallyfor promotion, consumption or evaluation. )

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The choice of strategies depends on minimization of cost &maximization of desirable characteristics.

The strategies should be selected on basis of following parameters:

1) Minimise the cost of pick & pack2) Minimise the shipping cost

3) Reduce the time required for each cycle

4) Increase the fill rate

5) Improve accuracy of the elements in process6) Traceability and accountability of all transaction

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Communication of picking directives

It consists of certain direction for picking of merchandise.

Report : It is customers order, pick lists, packing slip, stock locationreports, delivery notes.

Label : It is used to direct order pick location which are bar coded forsorting & order verification.

- Used for discrete order or batch selection methods.

Radio frequency terminals : They are used in combination of barcoded

shipping labels for sorting & routing.

Display lights : They are computer activated lights used to direct orderselector to items & location to pick order.

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Order picking & packing economics

It consists of 2 types of costs:

1) Capital cost ie. Non recurring like facilities, plant, material handlingsystem, supporting system.

1) Operating cost ie. Recurring like labour cost, consumable supplies,insurance, utilities, taxes.

Certain types of cost which incidental cost like damages, resolutionor errors, return handling, inventory shrinkage.

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Space & storage equipment cost

- It consists of cost of following :

Online storage for inventory

Replenishment aisles Picking aisles

Packing work space

Material handling space

- Depending upon size, quantities, patterns of use & velocity the on linestorage space is divided into pallet racks, case f low rack, bin shelving,carousel.

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Carousel Bin

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Bin shelving Pallet rack

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Storage density Vs. velocity Storage density refers to quantity of material or units that can be stored

in a perticular area.

It depends on average duration of storage & frequency of retrieval.

Velocity refers to the speed with which materials are moved into thestorage space & in the supply chain.

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