La logistica intelligente Logistics and operations: issues and - PowerPoint PPT Presentation

La logistica intelligente Logistics and operations: issues and challenges Prof.Ing.Emilio Ferrari Dipartimento di Ingegneria Industriale, UniBO 23 Maggio 2014, Cineca, Casalecchio

Agenda of the speech • Advanced problems and issues in logistics and operations • Advanced models and tools supporting decision making in logistics • Exemplifying problem complexity and results _Food supply chain _Picking and correlated storage _CNH Spare Parts (Eng . Tommaso D’Alessandro)

Issues & challanges (1) CO 2 € Manufacturing and material handling • Flexible manufacturing system (FMS) & cellular manufacturng • Layout determination and optimization • Line balancing (e.g. assembly system) • Reliability and maintenance engineering • Material handling (e.g. automated guided vehicles - AGV, LGV, etc.)

Issues & challanges (2) CO 2 € Logistic networks and Freight Intermodality • Planning intermodal freight infrastructure and networks. • Environmental impacts assessment of alternative transport modes. • Distribution planning and scheduling handling operations. • Clustering shipments in distribution planning. • Strategic analysis of urban networks for passengers and freight.

Issues & challanges (3) CO 2 € Reverse networks and waste management • Planning forward-reverse logistic networks . • Design closed-loop supply chain for the management of waste and by-products. • Assessment of environmental KPIs of reverse collection chain. • Measuring environmental performance of alternative packaging materials. • Collection fleet management and routing. • By products management

Issues & challanges (4) CO 2 € Quality traceability and logistics of perishable products • Enterprise touching base. • Tracking shipments with on-board data loggers. • Monitoring environmental stresses (temperature, humidity during logistics processes. • Lab simulation of transport conditions in climate rooms. • Sensorial and chemical analyses on stressed products to assess quality decay due to logistic processes.

Issues & challanges (5) CO 2 € Storage and warehousing system • Design order picking systems (OPS) and storage areas. • Storage allocation and storage assignment problems for perishable and non- perishable products. • Assessment of time, energy and space efficiency in handling and storage operations . • Design unit-load storage systems for beverage and bakery industry. • Simulation and scheduling of storage and retrieving activities. • Order-batching and zoning in OPS. • Automation

Case studies • Food supply chain • Storage system & warehosuing • CNH Spare Parts (Eng.Tommaso d’Alessandro) 2

Food Issues & Food Supply Chain Water Hunger supply Energy supply Demographic Development Urban/rural Climate balance change Land grabbing 2

An Integrated Perspective • The design of food supply chain as a whole, involves a broad set of processes and variables belonging to different stages from-farm-to-fork. • An innovative approach aims to integrate decisions of agriculture source (i.e., LUAP) with decisions of logistics planning (i.e., LAP) for the design of a sustainable forward- reverse food supply chain. Climate Soil Processing Distribution Consumption End-of-life Geography Storage cap. Manufacturing Spatial grid Thickness Solar Irradiance Food Demand Packaging cap. Storage mode Recycling flows Latitude Moisture Wind Retailer node Manufacturing Storage equip. Collection node Longitude Texture Temperature variable costs Transport mean Recycling node Altitude Structure Humidity Manufacturing Distribution fixed costs Collection cap. Population Carbonate Rainfall node Manufacturing Recycling cap. Resources Sodium Sundays Transport environmental environmental Evapo-transp. impacts impacts Agriculture decisions Logistics decisions 4

Land-use allocation Model • The proposed land-use allocation (LUA) model supports the design of sustainable agri- food production area. • Assume to consider the agriculture, logistic, energy and environmental use as potential land-use. • The objective is the minimization of carbon footprint (tons CO2eq) of the agro-food process including agriculture, food processing, and packaging through the adoption of renewable energy sources and mitigation strategies. 4

Location-allocation model • The proposed location-allocation model supports the design of sustainable food forward and reverse distribution networks. • Reverse networks support the collection of packaging materials, by-products or waste generated by production, storage or consumption. • The objective function account two-fold objectives of minimizing carbon footprint or costs of the closed-loop supply chains. Forward Flow Reverse Flow 4

An Integrated Procedure • Supporting the connection of agri-food production areas and demand over a global scale through the design of sustainable food supply chain: V Layer ** *** ** *** *** ** *** *** * *** * *** * *** * * *** *** *** * ** * *** *** * *** * *** *** * *** ** * * *** *** * ** * *** * * *** *** ** * *** * *** * * ** * *** * ** * * * * *** * ** * * * * *** ** * * * *** ** * * * * * * * * * * * * * * * * * * *** *** ** *** ** *** * *** * * *** * *** *** * * *** *** * *** *** * ** * *** ** * ** * *** * * * ** * * * * * * * * * * * * N W E S N N W E W E S ** S *** ** *** *** *** *** *** ** *** *** ** * * *** * *** * * *** * *** N N *** * * *** * *** * *** * * *** *** * *** * ** *** * ** * *** * * *** * *** ** * *** * *** * *** ** * *** ** * *** ** * * W E W E ** * * * * ** * * * * * * * * * * * * * * * * * * * * * * S S N N W E W E S S *** ** *** *** *** ** * * *** * * *** *** * *** * *** *** * * *** ** * *** ** * *** * * *** ** * ** * * * * * * * * * * * * * N W E S N N W E W E S S N N W E W E S S N N *** *** ** *** ** *** *** *** ** * *** * *** *** ** *** * * *** W E W E * * * *** * *** * * *** *** * *** * *** * *** *** ** * * *** * *** * ** * *** ** * *** * * * *** *** *** ** * *** * * *** ** * ** * * ** * ** * * * * * * * * * * * * * * * S S * * * * * * * * ** *** *** ** *** *** * *** * * *** * *** *** * * *** *** * * ** *** * ** * *** * *** * *** ** * ** * * * * * * * * * * * * * N W E S N N W E W E S S N N W E W E S S N N W E W E S S ** *** ** *** *** *** ** *** ** *** *** * *** * * *** *** * *** * *** * *** * *** * * *** * *** * *** * * *** *** ** * * *** * * *** ** * *** ** * * *** *** ** *** * * *** * *** ** * * *** ** * ** * * * * * * * ** * * * * * * * * * * * * * * * * * * * *** ** *** *** *** ** * * *** * * *** *** *** * *** * *** * * ** *** * ** * *** * *** * *** ** * ** * * * * * * * * * * * * * N W E S N N W E W E S S N N W E W E S S N N W E W E S S 4

Case study 1 - Supply Chain assessment monitoring, simulation and optimisation Logistic network of fresh products for a retailer company AS-IS TO-BE

As-Is vs To-Be – Impact Categories CO 2 CH 4 HC NO x HC NO x N 2 O Effetto Serra (GWP) Eutrofizzazione Smog Fotochimico NH 3 CO N 2 O CH 4 CO SO 2 HC Assottigliamento Acidificazione Strato Ozono Atmosferico NO x NH 3 HC

Case study 1 - As-Is vs To-Be – Impact KPIs Anidride Ossido di Protossido di Carbonica Azoto Azoto Monossido di Particolato Ammoniaca Carbonio Ossido di Idrocarburi Metano Zolfo

Storage system & Warehousing  Global supply chains continuously face criticalities related to material handling and logistic network.  Enterprises need to lead products from processing towards final consumer in a global context.  Logistics represents an opportunity as well as the main source of waste and costs. Distribution Center (DC) Warehousing system Material handling Inventory management Receiving/shipping Order picking Add value service

Supply Chain and Warehousing Customer Demand Product Distribution Center (DC) Supplying Warehousing system Order Picking sorting WIP Material handling Supplying Inventory management Checklist receiving Add value service shipping Unit-load picking time cost

Order Picking Systems  ORDER PICKING: process of retrieving products from a storage area in response to a specific customer request. Order Picking Efficiency Reducing travelled distance and time for retrieval missions  Minimize customer response time.  Decrease logistic costs.  Increase service level.

Questions in OPS 3 main problems in Fast Pick area optimization: 1. Which items we need to store in fast pick area? 2. Stock inventory level for each item in fast pick? 3. Where are the most suitable locations for each item? 2 3 STORAGE ALLOCATION STORAGE ASSINGNMENT STRATEGIES RULES Try to establish how much goods Try to establish where allocate stored in Fast Pick area is each stock within the Fast Pick required. area.  Which items we need to store in fast pick area?  Stock inventory level for each item in fast pick?  Where are the most suitable locations for each item?