Validation Using Simulation of a New Cross Docking Facility Design

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Validation Using Simulation of a New Cross
Docking Facility Design

• Presenters José Antonio Mesa R.
• Diego Mesa R.
• Javier Orjuela C.

Universidad Distrital Francisco José de
Caldas Bogotá, Colombia, South America.
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Validation Using Simulation of a New Cross
Docking Facility Design
SponsorsTwo Bogotás City Hall agencies
Fondo Local de Desarrollo de Ciudad
Bolívar.Unidad Ejecutiva de Servicios Públicos.
UESP.

• Team
• Javier Orjuela (Director)
• José Antonio Mesa R.(Developer)
• Diego Mesa R. (Analyst)
• Guillermo Urrutia (Designer)
• Francisco Soler (Designer)

Universidad Distrital Francisco José de
Caldas GICIC Research Team Bogotá, Colombia,
South America.
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Abstract

• Simulation with ProModel is being used
  succesfully in the validation process of a new
  logistic cross docking facility in Bogotá,
  Colombia, as part of a Master Plan intended to
  optimize the logistic process of food suplying
  and make possible, thanks to cost lowering, an
  efficient and economic solution for poor
  communities, and stablishing a proven technology
  for furthers developments.

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Presenters

• Javier Orjuela C. MSc Operations Research.
  Production Engineering Specialist. Industrial
  Engineer. Former experience in food plants.
• José A. Mesa R. Production Engineering
  Specialist. Computer Science Engineer. Former
  experience managing production plants and
  Simulation projects.
• Diego B. Mesa. Business Manager. Operation
  Management Specialist. Logistics Specialist.

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Application Summary

• The Universidad Distrital was contracted to
  develop a Market Study in order to build a whole
  new Food Distribution System intended to reduce
  the cost of food (It has been estimated that
  1000.000 people in Bogotá have only a food at
  day)
• Important inefficiencies had been found, and they
  generate a lot of wastes, increasing cost for the
  final consumer
• The second phase of the project lead to design a
  network of logistics facilities, using the market
  studies results.

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Application Summary

• A kind of facility must satisfy the market demand
  for a specific geographic zone, and its physical
  design and it procedures must be tested before
  making any final choice.
• The Simulation Model is being developed as part
  of the works of GICIC research group

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Agenda

• The problem
• The City Hall Food Suplying Master Plan
• The Model
• Goals
• Model Inputs
• Recomendations

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The Problem

• Validate the Design of a Crossdocking Facility
  where goods will be received via heavy trucks,
  organized temporaly in pallets and then disposed
  according summarized purchase orders sent to five
  logistic zones using smaller vehicles
• The facility must operate up to 230 tons of food
  daily, classified in 33 different items, this
  agregated demand satisfy the requirements of
  272.060 habitants and delivered through a network
  of 807 small stores located on an average
  distance of 1.6 kms.
• The model should allow formulate policies and
  deploy strategies to balance resources allocation
  to processes inside the facility

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Bogotá, Colombia, South America
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Briefing of Bogotá food supplying problem

• Bogotá is a city of 7000.000 people.
• Extremely Poor overpopulated communities, about
  30, could have only a meal at day
• They have a dietary deficience only receive 46
  of required calories and 20 of required proteins
• With extremely low salaries and laboral
  inestability, families uses 31 of their incomes
  in nutritional requirements
• Between 65 and 70 of the food market is buyed
  daily at the corners store

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But Bogotá could be Well Supplied

• Bogota requires about 10.000 tons of food daily
• 33 comes from the Ring one, Bogotá and 19 other
  near cities
• 44 comes from the Ring two, 4 near provinces
• 23 comes from the country and the world

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But Food supplying has been diagnosed Chaotic
and inefficient

• Inadecuate handling can produce at least 17 of
  wastes
• Packaging wastes are 9 of the total mass
  transported
• Big dealers and retailers operations adds 21 to
  cost
• Food marketing infraestructure underutilized
• Truck fleet is used only at 48

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Bogotás Food Supplying Master Plan

• A public policy to ensure that population will
  have acces to the consumption of meals and
  nourisments in conditions of
• Quantity
• Variety
• Quality and
• Inocuity

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Plan Principles
Citizens
Promote Food Access
Enviromental Sustainability
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SAAB (Food Supplying System)

• SAAB will allow that producers and small store
  owners can deal directly makin easier for they
  his operation in a supply chain knowing offer,
  demmand and prices.
• Improves costs because minimices the quantity of
  intermediaries and transport
• Food are well handled, processed and transported
• Improves life quality for the whole population

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Facilities (Equipments, Infrastructure)

• Logistics Management System
• Quality System (ISO9000, ISO14000, HACCP)
• Information System

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Facility before the project
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The Model

• Main Goal Validate one Design of the future
  Cross Docking Facility
• Design
• Physical
• Functional
• Procedural

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• Modeling the systems components and operations
  the team wished to obtain a simulation model to
  test, plan and manage the facility, identifying
  the possible bottlenecks and causes, capacity
  restrictions, possible response to different load
  levels, optimal resource quantities, trucks
  arriving schedule, results of contrasting
  technologies and required room to fit needs.

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Main Features

• Complexity
• Deterministic
• Reutilizability
• Visualization
• Flexibility

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Constraints

• Platform works from
• 0400 to 0800 Receiving (loading)
• 0800 to 1700 Delivering (Unloading)
• Only One direction at time, it means, Youre
  loading or youre Unloading, and you must finish
  loading to start unloading.
• Area 3000 sq mts (27000 sq ft)

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Complexity

• 83 locations
• 35 entities (Trucks, baskets, pallets)
• 3 lines of items
• From milk to cheese (dairy) and poultry to meat.
  6 types of entities.
• From tomatoes to Bananas. FRUVER. Fruits and
  Vegetables. 11 types of entities.
• From Sugar to Noodles. Groceries. 13 types of
  entities.
• Two Path Networks, 90 nodes

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Complexity

• 8 resource types (Delivering Trucks, forktrucks,
  pallet trucks, operators, lifters)
• Entity Attributes making easier programming.
  Entity basket uses an attribute that allows to
  determine the type of item, making easier the
  programming process

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Processing

• // Abarrotes
• // El peso en toneladas del camion es
  At_carga_en_camion Array_kilos_canastillaAt_Tip
  o_producto
• // Si viene con mas de 8 toneladas se descarga
  con 4 operarios a 4 ton/ min,
• // sino a N(7.5 , 1) ton por min con dos
  operarios
• IF At_carga_en_camion Array_kilos_canastillaAt_
  Tipo_producto lt 8000
• THEN
• USE 2 Op_descarga FOR (At_carga_en_camion
  Array_kilos_canastillaAt_Tipo_producto N(7.5
  , 1) / 1000)
• ELSE
• USE 4 Op_descarga FOR (At_carga_en_camion
  Array_kilos_canastillaAt_Tipo_producto 4 /
  1000)
• ORDER At_carga_en_camion ENT(At_prod_en_camion)
  TO Cola_ZI1

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How the three lines were chosen
Milk, potatoes, oranges, plantain and rice are
the top five, 55 of consumption!!

• Trying to balance the quantity of baskets loaded
  per line to the facility to ensure a permanent
  flow
• A previous market study was developed by GICIC
  research team
• These quantities were used to design the ideal
  fleet size and scheduling for loading platform

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Arrays

• Five arrays are loaded from an Excel? File
• Demanded baskets for each product
• Kg of each product in a basket
• Basket per pallet
• Baskets per truck

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Shifts

• Load operators, movers,
• Unload operators, people preparing orders,
  deliery trucks
• Fork trucks, pallet trucks

• Facility Load resources and locations (0400 to
  0800 hrs)
• Facility Unload resources and locations (0800 to
  1700 hrs)
• Mixed

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Shifts

• Loadingfacility
• Unloadingfacility

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Atributes
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Model inputs (arrivals file)

• An Excel? File containing registers of trucks
  arriving to the platform, arrival time, type of
  product and baskets quantity transported in each
  truck.
• This is the base of flexibility

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After loading is complete

• Start preparing purchase orders, send trucks (3
  tons) and deliver them to five different logistic
  zones!!!

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Output processing

• Groups of orders are prepared inside each
  delivering truck and sent to each one of five
  logistics zones
• Final orders per store are prepared at the store
  front
• This proces was not detailed deeply, the main
  scope were operations inside the platform

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Final design after adjustments
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Final design after adjustments
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Final design after adjustments
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Dynamic Plots
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Benefits

• Number of Parking lots for Trucks in system were
  determined (14)
• Trucks permanence in system (average 84.21
  minutes) was determined

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Future Aplications

• Test other 17 platforms (City Logistics)
• Define costs and Include ABC methodology
• Create a Big model
• Once running, stochasticity will be measured and
  implemented to the models

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Thanks!!

• José Antonio Mesa R. josemesa_at_hotmail.com
• Diego Mesa R. diegobmesar_at_yahoo.com
• Javier Orjuela jorjuela_at_udistrital.edu.co