Advanced methodologies in production CAD & Computer Integrated Manufacturing Split case order fulfillment methods Communication of picking

ing directives Order picking & packing economics Capital costs for online storages

CAD
CAD means Computer Aided Design. CAD is the use of computer technology to aid in the design and

particularly 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 or intranet. It can create the volume, weight of components, CG, deflection under estimated load, design parameters. It reduces time required to make a design or modify a product. Laborious mechanical drawing or complicated calculations can be done very easily. Analysts use CAD to store, retrieve and classify data of various parts.

Computer integrated manufacturing

It is the complete automation of a manufacturing plant, with all -

processes functioning under computer control & digital information. It includes functions like production, design and management function. Three main computer aid in CIM are : Computer aid to production function ( automated flow of materials ) Computer aid to the design function ( automated flow of technological information ) Computer aid to the management function ( automated flow of management information ) It increases the customer satisfaction as response time decreases. It enhances throughput & better utilization of space. Eg. Barcoded labels, RFID tags.

 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 and

better utilization of space.

At present 40 % of manufacturing companies are now using CIM

technology in different forms.

Split case order fulfillment method

It is used when the customer requires different merchandise in -

different quantities. The cases are splited, pieces are picked & repacked according to requirement of customer. It improves identification, pick up & repacking of materials and reduces monotony of workers. It includes Order picking methods Sorting and routing Order packing methods Classification schemes Choice of optimal fulfillment strategies

Order picking method

(1)

Order extent : It represents the numbers of order simultaneously picked 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 fulfill the 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.

(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 for picking merchandise.

Sorting & Routing

Sorting helps in matching orders and merchandise for customers. As & when orders are picked they are sorted or merged according to

area of zone, no.s of orders, type of material. The strategy depends on the area of the zone, number of orders, type of material. When orders are passed among various zones where picks are required according to customers requirement it is known as routing. When orders are routed from zone to zone in an order with or without pick it is known as chaining. When multiple zones are covered simultaneously it is known as parallel routing.

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 for packing.

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

1st letter : D for discrete order picking (or) B for batch order picking

2nd letter : Z for zone picking (or) T for tour picking

3rd letter : Pack Immediate (0r) Assemble and pack For ex. DZA means discrete order picking system where picker covers the entire zone picking area ad then assembles and packs the order as it is selected.

 1st letter : Bs batch order picking - Sort immediate

Bm batch order picking - Merge & sort

2nd letter : 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 with immediate sorting and assemble.

Choice of optimal fulfillment strategies

1) 2) 3) 4)

It depends on order characteristics & category of distribution General order categories are: Wholesale distribution ( large nos of pieces of a few item ) Retail distribution ( large nos of pieces for a large nos. of items ) Direct marketing ( small quantities ) Consumer distribution ( small quantities of different items usually for promotion, consumption or evaluation. )

The choice of strategies depends on minimization of cost & maximization of desirable characteristics. The strategies should be selected on basis of following parameters: Minimise the cost of pick & pack Minimise the shipping cost Reduce the time required for each cycle Increase the fill rate Improve accuracy of the elements in process Traceability and accountability of all transaction

1)

2)
3) 4) 5)

6)

Communication of picking directives

It consists of certain direction for picking of merchandise.

Report : It is customers order, pick lists, packing slip, stock location

reports, delivery notes.

Label : It is used to direct order pick location which are bar coded for

sorting & 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 order

selector to items & location to pick order.

Order picking & packing economics

1)

It consists of 2 types of costs: Capital cost ie. Non recurring like facilities, plant, material handling system, supporting system.

1)

Operating cost ie. Recurring like labour cost, consumable supplies, insurance, utilities, taxes.
Certain types of cost which incidental cost like damages, resolution or errors, return handling, inventory shrinkage.

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 line storage space is divided into pallet racks, case flow rack, bin shelving, carousel.

Carousel

Bin

Bin shelving

Pallet rack

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 the

storage space & in the supply chain.