SBC_Group_DC_Expert

DC EXPERT 3.5 Offered by: Stockbridge Consulting Group
161 Ottawa Ave. Suite 405B
Grand Rapids, MI 49503
(800) 809-2515
www.inside-sbcgroup.com

Thursday, June 14, 12

PRODUCTS AND SERVICES

 Enterprise  Desk Top
 Transportation Management DC Expert

System
Transportation Routing &
Transport Planning System 
 Scheduling

 Strategic  Professional Services
 Strategic Logistics Modeling  Consulting
 Health Check
 Implementation


INSIGHT CLIENTS
 Enterprise Logistics (UK)  Rohm and Haas
 3M  Moen
 Hannaford Bros.  Sobeys
 Acklands Grainger  Fruit of the Loom
 Thyssen Krupp  Cadbury
 Ryder Logistics  Foodstuffs and Gilmours
 Lennox  Fosters Group
 Corporate Express  Spectrum Supply Chain
 Nissan Canada Solutions
 Karry’s Wholesale  Mainfreight International
 Grace Kennedy  Unilever
 Nestle  Alpha Distribution Solutions
 Bridgestone  Apollo Health and Beauty


DC EXPERT 3.5
 Maximize your warehouse facility
 Increase the cubic utilization of the facility
 Decrease overall travel distance and handling in the facility
 Apply new or existing models in the warehouse against each
other for proof of concept and ROI discussions.
 Increase warehouse ﬂexibility to handle new or seasonal
products
 Quickly react or predict labor requirements
 Create a standard set of terminology and tool set for the
entire supply chain operation

Comprehensive warehouse slotting and planning (including
zone and work balancing


INTEGRATION OF MODULES

Reports
Data File Data File Export
Other
Planning
Data

SKU Rack Selection Dock Planner Benchmark
Data

Warehouse
Layout
DXF/CAD Applications
Microsoft Excel Reports

Slot Master Reports
Data File Exports


WHY DC EXPERT?

 DC Expert is the only product on the market to integrate all aspects
of warehouse planning in one tool set

 Interface and data requirements for DC Expert are simple yet
unique. Using Access or Excel or CSV formats, any existing
enterprise system can feed DC Expert data.

 DC Expert is the only planning product to combine warehouse
design, location coordinates and slotting in one tool


WHY DC EXPERT?
 Slot Master provides unique ability to slot through logical
location or physical location

 Slot Master automatically calculates cube utilization based
on SKU analysis by location

 Pre Proﬁler in Slot Master automatically calculates bay,
shelf, bed or location proﬁles and totals for the facility.

 Over 100,000 Algorithms in DC Expert

 Benchmark tool allows users to calculate activity KPI’s and
then forecast labor and MHE requirements.


DATA TEMPLATE


FILE DESCRIPTION
Field Type Field Size Req'd RS SM Example Description
WHSE TEXT 10 Y 1 The warehouse ID
ITEM TEXT 25 Y AB123 The SKU number/code as an unique item identifier
ITEMRANKING NUMBER SINGLE Y 2 User entered rank of each product - for manual algorithm
ITEMRANKINGEXPRESSION EXPRESSION 40 Y Formulated expressions used as criterion on which to sort each item
UPCCODE TEXT 14 N 1234-5678 Standard UPC code per client - not required
DESCRIPTION TEXT 40 N Merlot Standard Product Description at the SKU level
PRODFAM TEXT 10 Y Wines Standard product grouping field - defined as text
FAMRANKING NUMBER SINGLE Y 1 User entered rank of each family group
FAMRANKINGEXPRESSION EXPRESSION 40 Y Formulated expressions used as criterion on which to sort each family
SUPPLIERCODE TEXT 25 Y 26453 Supplier item code which is used to identify the suppliers item
SUPPLIERCODE TEXT 20 Y ABC Wines Supplier description or name
CASESLAYER NUMBER LONG INTEGER Y 4 Number of cases per layer
LAYERSPALLET NUMBER LONG INTEGER Y 3 Number of layers per pallet
UNITSMASTERCASE NUMBER LONG INTEGER Y 12 Total numbers of units in a master case ("sum of Inners")
MCASEBREAK NUMBER BYTE N Part of an upgrade path - leave blank!
MCASEHEIGHT NUMBER SINGLE Y 5 Master case height in inches or metres
MCASELENGTH NUMBER SINGLE Y 10 Master case length (depth) in inches or metres
MCASEWIDTH NUMBER SINGLE Y 8 Master case width in inches or metres
MCASEWEIGHT NUMBER SINGLE Y 200 Mcase case weight in pounds or kilograms


FILE DESCRIPTION
Field Type Field Size Req'd RS SM Example Description
PHEIGHT NUMBER SINGLE Y 6 Height of the pallet in inches or metres
PLENGTH NUMBER SINGLE Y 48 Length (depth) of the pallet in inches or metres
PWIDTH NUMBER SINGLE Y 40 Width of the pallet in inches or metres
ACTIVE NUMBER BYTE Y 1 1 = Yes; 0 = No: Is the product an active SKU?
FLOORSTACK NUMBER BYTE Y 0 1 = Yes; 0 = No: Is the product floor stackable/floor bulk?
DECANTABLE NUMBER BYTE Y 1 1 = Yes; 0 = No: Is the product hand bombed inbound/outbound?
TOTEABLE NUMBER BYTE Y 1 1 = Yes; 0 = No: Is the product stored in a special bin or fixed container?
SPECIAL NUMBER BYTE Y 1 1 = Yes; 0 = No: Is the product specially flagged (user specified)
PREPROCESS NUMBER BYTE Y 0 1 = Yes; 0 = No: Is their a pre-process for this product?
STACKHEIGHT NUMBER LONG INTEGER Y 0 Applies ONLY if FLOORSTACK = 1: Defines height of the stack on the
CRUSHABLE NUMBER SINGLE Y 0 floor
TOXICITY NUMBER SINGLE Y 7 Scale from 1-99999: Based on fragility of the picked product
AVEACTIVITY NUMBER LONG INTEGER Y 18 Scale from 1-99999: Based on hazardous nature of the product
BOH NUMBER LONG INTEGER Y 72 Number of Pallets (or Pallet Equivalents) picked per week
BOHPERCENTINPFACE NUMBER % AS DEC. Y 1 Actual number of pallets on hand (pallet quantities) - snapshot
MIN_IN_PFACE NUMBER LONG INTEGER Y 0 The Percentage of Total BOH Required in the Physical Pickface
MAX_IN_PFACE NUMBER LONG INTEGER Y 99999 The min.amount in the pick face as assigned by the user (def = 0)
PICKFACESLOTS NUMBER SINGLE Y 3 The max amount in the pick face as assigned by the user (def = 99999)
PICKFACE_CUBEFILL_% NUMBER % AS DEC. Y 0.55 The number of allocated pick face slots - manually defined by user
CASEPICK NUMBER BYTE Y 1 The percentage of cube required to be filled within the pick face
LOCID NUMBER TEXT N D1203A1 1=Casepick, 0=Pallet Pick
User's naming convention or nomenclature


RACK SELECTION

 Rack Selection provides the Macro slotting functionality of
what type of medium should a product be stored and
picked from

 Looking at both the physical Fixed costs of a medium and
the variable costs around productivity, Rack Selection
provides a SKU by SKU analysis of the lowest cost solution

 Rack Selection allows users to compare a multitude of
storage mediums and real or forecasted data to create
models for actionable management decisions


RACK SELECTION PROCESS
Item Rack A Rack B Rack C Item Rack Type Rank Variable ($) Calculates ﬁxed
Creates a 1 1 A 1 1,500 and variable
Matrix 2 1 B 2 1,621
costs then ranks
3 1 C Fail 711
4
each rack type
5 2 B 1 1,782
for each item
2 A 2 1,972
2 C Fail 1,172
Item Rack A Rack B Rack C
Check for 1 Y Y Y 3 B 1 3,287
2 Y Y Y 3 A 2 3,982
ﬁt in rack
3 Y Y N
type
4 Y N N 4 A 1 1,224
5 Y N N
5 A 1 1,311

Item Rack A Rack B Rack C
1 Y Y Y
Removes 2 Y Y Y
racking 3 Y Y N
based on 4 Y N N
minimum 5 Y N N
s Min SKUs YES YES NO


DOCK PLANNER
Within the Dock planner module from the
menu
 Select Mode | Settings
 Select General Settings Change
Button
 The parameters are used to build up:
 Dock area
 Sundry pallet area
Total
Depth

Total Width


WAREHOUSE LAYOUT
Columns and
column logic Docks
and
Doors Calculated
Racking
Data

Office/marshalling area
Physical Coordinates


WAREHOUSE LAYOUT
 Input Pallet dimensions.
 Input Pallet clearance, lift off space, ﬂue space (of use default).
 Software automatically builds the racking to those speciﬁcations.

Chamber
height
Lift Off
Space
Pallet Pallet Pallet Pallet
Beam

Upright Pallet Pallet
Pallet Pallet
Beam

Pallet Pallet Pallet Pallet

Clearance Flue


SLOT MASTER

 Slotting warehouse in
family groups.
 Run different pick
sequences in different
sections of the
warehouse.
 Able to handle product
toxicity ratings.
 Hundreds of different
slotting scenarios to chose
from.
 Compare different sort
criteria against each other
to ﬁnd optimum slot
order.


SLOT MASTER

1 2 7 8 9
Chamber A
Aisle AA
3 4 5 6 10

19 18 17 12 11
Aisle AB
20 16 15 14 13


SLOT MASTER
 The user can deﬁne
pick paths through
the warehouse
moving from bay to
bay
 Sawtooth
 Z Pick Path
 U Pick Path
 Serpentine

 From this, the user
can deﬁne the vertical
component of a multi
level pick path


SLOT MASTER
 Can Support multi-level
Picking
 Multi-levels & multi sections
/ bay
 The user can define the pick
slot path the size of the
shelves.
 Velocity levels can also be
defined
 Green: Fast
 Gold: Medium
 Red: Slow
 These profiles can be saved
and applied to an individual
bay or aisle.


SLOT MASTER
 Slot Master allows the user to import existing locations from ERP or WMS
system and use as a baseline to optimize the operation.


SLOT MASTER
 Slotting Fundamentals
 Slot by SKU Characteristics, order proﬁles or family group
 Slotting supports
 zone picking
 velocity
 Weight
 Cube
 Slot Capacity
 Seasonal
 Custom Algorithms
 Location and Center of gravity models
 Multiple pick Sequencing


SLOT MASTER
 Slot Master
optimization wizard
allows the user to
lock or select either
SKU or location to
eliminate or include
in a particular run.
This feature is ideal
for slotting new or
seasonal product
into the warehouse.


SLOT MASTER
 Cube Utilization
 After slotting the product Slot Master will produce location
and utilization statistics
 Maximize the storage density in your operation with
measurable statistics.


SLOT MASTER-HEAT MAPPING

Automatic Heat
Mapping reports
displays velocity plan
in the warehouse
 Easily created by two
mouse clicks, no
cutting or pasting

24


BENCHMARK
 Benchmark uses 5 industrial engineered data bases to
calculate average KPI’s within an operation

 Benchmark captures 72 pieces of information (17 Critical) to
calculate work levels and performance measure

 Benchmark provides a unique comparison to industry
averages and target performance

 Benchmark provides the basis for activity based costing in
the operation, a key necessity for professional logistics
operations

 Benchmark provides a mathematical representation of the
22 touch points of labor in an operation, and the key to
balancing the labor resources amongst the tasks.


BENCHMARK LAYERING
 We use layering to evaluate different parts of the business
 We can make decisions on how to change the operation of
certain product groupings and make them more efficient

Entire ABC ABC of
Business Analysis By Customers Customers

A: 200 A: 200
Or Families
CS/Hr CS/Hr

B: 175 B: 175
Second Level ABC
CS/Hr Second Level CS/Hr
Analysis of
145 ABC Analysis 145 Customers
CS/Hr CS/Hr
A2: 120 A2: 120

C: 105 B2: 105 C: 105 B2: 105
CS/Hr CS/Hr
C2: 85 C2: 85


BENCHMARK

Text Text Text Text Text Text

Activity over extended
standard
under
utilized

Time

The Problem
 Work mirrors activity
 Under the standard represents under utilized labour
 Over the standard typically represents overturn


RETURN ON INVESTMENT (OPS)

 Typical travel distance is reduced by 10-30%

 Based on industrial averages, 50% of direct labor in the
warehouse is related to travel.

 Properly slotted facilities can reduce overall labor
requirements from 5-15% (could be higher if a WMS is
used).

 Reduced travel distance also reduces the maintenance
and operating costs of MHE by 5-20%.


RETURN ON INVESTMENT
 Properly slotted facilities increase the storage density by up
to 30%.

 Handling can be reduced by up to 50% based on improved
ergonomics and Adjacencies. ( i.e. Weight, crushability,
family grouping).

 Product damage is reduced by having the right product in
the right slot type and pick sequence.

 By segregating products in FMS ( Fast, medium, slow) space
utilization on the base level can be dramatically improved.


SAMPLE ROI CASE
 $4,000,000 operation

 50 warehouse staff

 150,000 sq.ft facility @ $6/sq.ft.

 5000 SKU’s

 5000 orders per week ( 4 lines per order)

 50% bulk pick, 50% each pick

 16 Material Handling Vehicles

 Current throughput 42 units/hr/FTE


SAMPLE ROI

 Decrease travel by 10%
 Net Value on Labor reduction $120,000
 Decrease handling by 15%
 Net Value on Labor reduction $ 30,000
 Increase Storage Density 15%
 Net Value on space costs (7500 Sqft) $ 45,000
 Decrease MHE requirement 10%
 Net Value on maintenance and rental $ 5,000
 Decrease error rate by 10%
 Net value on labor reduction $ 4,000

Total Return on Investment
$204,000


ABOUT US

Management Consulting

DC Expert 3.5

Warehouse Management

Transportation Planning

Logistics HealthCheck™

Offered by: Stockbridge Consulting Group
161 Ottawa Ave. Suite 405B
Grand Rapids, MI 49503
(800) 809-2515
www.inside-sbcgroup.com

SBC_Group_DC_Expert

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