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1. IJfs, S.R. Improving the Logistical Process Around Cross-Docking of Products from Packaging Lines: A Case Study at the Zoeterwoude Brewery of HEINEKEN Nederland Supply:.

Degree: 2015, Delft University of Technology

HEINEKEN Nederland Supply continuously strives to improve its logistical processes in order to be able to serve its customer better, but at the same time to reduce costs. Within the Zoeterwoude Brewery, the Customer Service & Logistics department is responsible for the supply of the materials to the packaging lines, but also for the loading process of the pallets arriving at the warehouse. Increasing output from the packaging lines have caused regular spill-back of finished goods towards packaging line 2, 4 and 7. This spill-back causes standstill of the filling machine and therefore a drop in the performance of the packaging lines. HEINEKEN Nederland Supply has a large number of open sales orders and is already producing in over-time. This means that every lost production hour leads to sales losses for the company and the potential loss of valuable customers. The objective is to improve the loading process such that the capacities and planning are better aligned with the supply of the packaging lines. This leads to the following research question: How can the loading process at the Zoeterwoude Brewery of Heineken Nederland Supply be improved such that the capacities within the process and the corresponding planning are better aligned with the supply of packaging line 2, 4 and 7? This research is framed within the DMAIC methodology (and performed by following on the Theory of Constraints). This research starts by analysing the current loading process and influencing factors. It is found that the amount of pallets that is being processed by CS&L is growing at a fast rate. Especially the loose-loaded pallets are leading to an increase in pallets. The share of these pallets grew in total from 6% in 2012 to 12% (even 43% for packaging lines 2, 4 and 7) in 2014 and is expected to grow even further. The process is found to be a complex socio-technological part of the brewery and is influenced by many factors, both controlled internally and externally. The next step in this research was to collect data related to this process and to obtain valuable information from different viewpoints. From the analyses the root-causes of the problem are found. From the bottleneck analysis it is found that the transfer car between the cross-docks and the loading stations is not able to handle certain product combinations entering the warehouse. The capacity of the loading operators is sufficient, although requiring two skilled operators. Unexpected disturbances lead to buffers (cross-docks) being occupied, after which the process is not able to restore itself because of a lack of over-capacity of the transfer car. From the remaining analysis it was found that the unexpected disturbances to the process are problems with the availability of containers, human errors, lack of communication, lack of skilled operators and the lack of warehouse capacity. The loading process can be improved by reducing the input to the cross-docks. This can be done by limiting the flow from line 41 and 42 by removing the pallets locally. Another solution is to… Advisors/Committee Members: Verbraeck, A., Duinkerken, M.B., Lukosch, H.K., Hoondert, P..

Subjects/Keywords: cross-docking; Heineken; logistics; packaging lines; spill-back; cross-docks; production

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APA · Chicago · MLA · Vancouver · CSE | Export to Zotero / EndNote / Reference Manager

APA (6th Edition):

IJfs, S. R. (2015). Improving the Logistical Process Around Cross-Docking of Products from Packaging Lines: A Case Study at the Zoeterwoude Brewery of HEINEKEN Nederland Supply:. (Masters Thesis). Delft University of Technology. Retrieved from http://resolver.tudelft.nl/uuid:06e6286f-8f3a-4d76-a4e9-fc4f6e267844

Chicago Manual of Style (16th Edition):

IJfs, S R. “Improving the Logistical Process Around Cross-Docking of Products from Packaging Lines: A Case Study at the Zoeterwoude Brewery of HEINEKEN Nederland Supply:.” 2015. Masters Thesis, Delft University of Technology. Accessed October 18, 2019. http://resolver.tudelft.nl/uuid:06e6286f-8f3a-4d76-a4e9-fc4f6e267844.

MLA Handbook (7th Edition):

IJfs, S R. “Improving the Logistical Process Around Cross-Docking of Products from Packaging Lines: A Case Study at the Zoeterwoude Brewery of HEINEKEN Nederland Supply:.” 2015. Web. 18 Oct 2019.

Vancouver:

IJfs SR. Improving the Logistical Process Around Cross-Docking of Products from Packaging Lines: A Case Study at the Zoeterwoude Brewery of HEINEKEN Nederland Supply:. [Internet] [Masters thesis]. Delft University of Technology; 2015. [cited 2019 Oct 18]. Available from: http://resolver.tudelft.nl/uuid:06e6286f-8f3a-4d76-a4e9-fc4f6e267844.

Council of Science Editors:

IJfs SR. Improving the Logistical Process Around Cross-Docking of Products from Packaging Lines: A Case Study at the Zoeterwoude Brewery of HEINEKEN Nederland Supply:. [Masters Thesis]. Delft University of Technology; 2015. Available from: http://resolver.tudelft.nl/uuid:06e6286f-8f3a-4d76-a4e9-fc4f6e267844

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