Petrochemical enterprises automated library era *** enjoy the contradictions and response to the pallet

Petrochemical enterprises automated library era - *** enjoy the contradictions of the pallet and response

Foreword

In recent years, along with the rise of manpower and land factor costs, China's petrochemical enterprises warehousing and logistics upgrades to accelerate the demand for automated three-dimensional library construction outbreaks, some of the large-scale petrochemical enterprises have been set up covering the packaging, palletizing, sleeving, warehousing, storage, out of storage, loading and unloading of trucks, etc. The intelligent logistics system. The whole process of intelligent logistics system, the whole process of standard pallet as a storage unit, measurement unit, information unit media consistent intermodal transportation, in order to improve the overall supply chain management efficiency, reduce logistics costs, enhance product competitiveness.

The whole chain of palletized transport operations with an automated three-dimensional warehouse as the hub center is highly dependent on the level of pallet standardization, and at the same time, in the context of dual-carbon, petrochemical companies pay more attention to the sustainable green recycling logistics model, while replacing the disposable packaging to achieve the goal of palletized transport **** enjoy the pallet just fit this need.

In this paper, we analyze the problems, reasons and solutions of the actual pallet operation in the automated warehouse + **** enjoy pallet mode of petrochemical enterprises, mainly from the **** enjoy pallet operation status quo.

I. Background

Petrochemical enterprises plane library era gradually decline

1, rising labor costs

History, due to China's labor abundance at that time, and at the same time in the petrochemical plant construction of land acquisition, the need to solve the problem of employment resettlement in the local area, coupled with the low cost of labor, petrochemical enterprises more than the use of plane library. Manual loading and unloading + forklift warehouse operations, basically able to meet the needs of petrochemical enterprises warehousing logistics during this period. However, along with the aging of China's population, labor costs have risen sharply, willing to engage in heavy manual labor of the low-end employment group is becoming less and less, petrochemical companies generally realize that the construction of flat warehouse and rely on a large number of manpower loading and unloading operations of the traditional warehousing path has gone out of business.

2, rising land costs

With the large petrochemical companies world-class refining base size of the initial formation of production to intensive, large-scale development of petrochemical companies to greatly increase production capacity, million tons of solid product production units abound. In the past, solid products were stored in the form of pallet stacking in the planar storage, with 2 to 3 layers of product stacking layers, low storage efficiency, and the storage form of planar storage inevitably relies on large-scale land resources. In the face of restricted land area and rising land costs, petrochemical companies prefer to use the limited land resources for production, resulting in more and more intensive storage land.

3, management refinement requirements are increasingly high

With China's economic level and consumption level, downstream customer demand for petrochemical products from a single category, low-end products, to diversified, high-end products, a single customer demand continues to increase, and downstream customers on the product quality, timeliness requirements are also improving, petrochemical products market competition is quite fierce. In order to better meet customer demand, petrochemical companies continue to enrich the product range, product grade from the original five or six to hundreds. The traditional planar storage is manually assigned storage locations and managed in the traditional way of making records, inserting plates, labeling, and so on. With the increase of product grade, multiple grade products need to be stacked on a stack, which makes the original low efficiency, high error rate of the manual management form is difficult to cope with; the upper layer of the warehouse pallet and the lower layer of direct contact with the product, poor stability, easy to collapse, and the forklift trucks in the upper layer of the product, easy to appear pallet scratched the lower layer of the phenomenon of the product packaging; warehouse application of manually driven forklift palletizing stacking of the product, because the library is mostly Concrete floor, forklift operation rolled up a lot of dust and exhaust emissions of particles adsorbed in the product bags, affecting the appearance of the packaging, the health of employees is not good, affecting the quality of downstream products, but also damage the corporate image.

Second, the current situation

Petrochemical enterprises automated three-dimensional warehouse + **** enjoy the pallet - with the pallet transportation era is accelerating

1, three-dimensional warehouse operation process

The product through the fully automated packaging palletizing production line, the beam-type high palletizer will be palletized bagged products on the pallet, and by the automatic laminator laminating machine. Storage, through the ring shuttle/conveyor line into the automatic three-dimensional warehouse storage aisle, by the high stacker palletizer handling to the warehouse designated cargo space. The pallet information carrier adopts RFID technology to record the information of palletized products in the packaging and palletizing process, and match with the information in the warehouse management system (WMS), and only the products that match successfully can enter the warehouse. On the contrary, the same applies to the outgoing warehouse. Loading and unloading, for the whole pallet out of the warehouse transportation of products, the general use of "artificial + forklift" form of product handling to the designated vehicle, or the use of unmanned loading machine for automated loading.

Automated three-dimensional warehouse with high land utilization, highly automated, highly informatized, less labor costs and other advantages, to achieve the product from the automatic packaging into the warehouse, storage, out of the warehouse shipping and other automated operations and information management. The use of automated three-dimensional warehouse storage is gradually replacing the traditional warehousing methods to meet the development needs of the petrochemical industry, help enterprises to improve management and service, and realize the intelligence of warehousing and logistics, automation upgrade. Therefore, the use of intelligent three-dimensional warehouse to realize the handling of chemical products, storage and other automated logistics operations, become the inevitable trend of industry development.

In addition to fewer production units, annual output of less than 300,000 tons of small petrochemical enterprises, most of the large domestic petrochemical companies in the construction of new projects will be used in automated three-dimensional warehouse, petrochemical industry automated three-dimensional warehouse construction has entered into the outbreak of the period, and has begun to take shape. Quanzhou Sinochem, Zhenhai Refining, Zhongke Refining, China-Korea Petrochemical, Yangzi Petrochemical, Guangdong Petrochemical and other large petrochemical enterprises have taken the lead in the realization of the whole process of the construction of an intelligent logistics system, and has generated considerable repercussions in the industry.

2, with the bracket transportation to become a petrochemical enterprise automated three-dimensional library era inevitable

The traditional way to base on the internal logistics operation link optimization, in order to achieve the reduction of logistics cost opportunity space has become more and more limited, and stand in the whole supply chain point of view, by improving the level of standardization of logistics, improve the turnover rate of inventory or logistics facilities, reduce the number of manual overhand, in order to achieve the Logistics cost reduction and efficiency is the inevitable choice.

In the context of the construction of three-dimensional warehouse, the petrochemical company's logistics operations are more systematic and integrated, and the management concept is also transformed from logistics (logistics) to SCM (supply chain management). Traditional logistics management emphasizes the integration of various logistics links within the enterprise, while supply chain management pursues the integration of the logistics of all chain enterprises in the process of product circulation, including intermediate distributors, up to the end customer's overall logistics costs. Consistent upstream and downstream transportation with support allows the realization of the concept of supply chain management, improve the efficiency of upstream and downstream convergence, improve the turnover rate and reduce the loss of goods and logistics costs.

3. ***Hang pallet is the optimal way to realize consistent palletized transportation

***Hang pallet upstream and downstream intermodal transportation supports the realization of consistent palletized transportation solutions. In the past, the industry generally preferred to use the depalletization method to load trucks for transportation to obtain a higher loading rate; upstream and downstream enterprises lacked the norms of pallet settlement for pallet transportation, and there were many manufacturers and downstream users, and there was a lack of unified planning for the form of pallets and the flow of the recycling process. In recent years, along with the rising labor costs and land costs, automated three-dimensional warehouse + integrated construction and operation with pallet transport has obvious cost advantages, and easy to form a high viscosity of products and services to downstream customers, three-dimensional warehouse + *** enjoy the pallet with pallet transport mode in the petrochemical enterprises began to popularize the application. Under the vigorous promotion of PetroChina, Sinopec, China Shipping Shell, Wanhua, some private petrochemical enterprises are also gradually joining; the emergence of the third-party professional pallet operation service providers, solving the pallet asset management, recycling, cross-business settlement, and cleaning and maintenance after the pallet transportation; and China's overloading control of freight vehicles is increasing, and once through the depalletization of transport overloading to profit way has been Difficult to realize, with the pallet whole pallet transport began to be accepted by enterprises in the petrochemical industry, to the automated three-dimensional warehouse + consistent with the pallet transport model landing application provides a convenient condition.

Disposable pallets and recycled **** enjoy pallet comprehensive survey scores

Three, automated three-dimensional library + **** enjoy the contradiction in the operation of the pallet mode

Automated three-dimensional pallet requirements characteristics

Petrochemical enterprises automated three-dimensional warehouse on the use of the pallet standardization requirements are very high, otherwise it is very easy to cause production accidents, which is reflected in the following characteristics:

① large amount of

A vertical warehouse is usually 2 to 50,000 storage space, the tray in and out of the warehouse flow is usually more than 200 trays / hour, the daily tray replenishment is usually more than 2,000.

② in and out of storage operations are concentrated

is a "big in and out", and the peaks and valleys are obvious, the petrochemical warehousing area in the field of spare pallet storage space is generally insufficient, which requires the pallet service provider to provide JIT mode of flexible replenishment.

③ library automated operation of the tray reliability requirements are extremely high

The tray test standards are much higher than GB/T35781-2017 "tray *** with system plastic flat tray" performance requirements, it is estimated that can meet the requirements of the use of standing library of plastic trays production costs are generally in the more than 400 yuan / a. The tray is a continuous process industry, and the peaks and valleys are obvious, which requires pallet service providers to provide JIT mode of flexible replenishment. Petrochemical production belongs to the continuous process industry, never allow the middle of the shutdown, intelligent three-dimensional warehouse as the last link of the continuous process industry, do not allow the occurrence of upstream shutdown due to operational failures caused by the occurrence of accidents.

Take a petrochemical vertical warehouse as an example

The technical requirements of its vertical warehouse pallet are as follows:

And GB/T35781-2017 "pallet **** with the system of plastic flat pallet" load capacity requirements are as follows:

2, **** enjoy the pallet operation contradictions and problems Domestic **** enjoy the operation of the pallet is in the early stages of the industry's development, unlike the foreign mature Developed economies, has generally formed the habit of pallet rental management, that is, the pallet user has a special area to be recycled classified storage *** enjoy the pallet, there are special personnel to the pallet assets into the warehouse confirmation, inventory, return operation and cost reconciliation and settlement. As a result, the current domestic three-dimensional library + *** enjoy the application of the pallet model still exists in the following contradictory points.

*** Enjoy the contradictions existing at the current stage of the pallet operation

01 downstream scene is complex, the operation is not standardized, back to the pallet breakage rate is high, *** Enjoy the pallet into the warehouse again need to go through a rigorous screening (such as whether the support structure is damaged, whether the RFID is lost, whether the light-sensitive bit is damaged, whether the burr fly edge is protruding, whether the steel pipe is rusted, etc.), or else it is difficult to meet the requirements of the three-dimensional warehouse direct use The high rate of withdrawal from storage will lead to the need for manual restructuring.

02 downstream customers, the petrochemical industry in the general distribution model, the pallet flow process is complex, the pallet loss rate is high. And standing library pallet production costs are high, the price is usually more than 400 yuan / a, once a high percentage of loss, the pallet owner will cause significant ongoing losses. In the case of non-differentiated blind hair (i.e., in fact, can not pass the responsibility for tray loss, damage to the tray user), the tray loss rate of even more than 10%, thus, in the case of other operating costs are not taken into account, alone apportioned to the tray operation on the *** enjoy the pallet single piece of the sub-loss cost of more than 40 yuan, obviously, this is not a healthy operating model. If this loss cost is borne by downstream pallet using customers, it is obviously difficult for downstream customers to accept, and by the *** enjoy pallet operators to bear, is also difficult to sustain. To solve this contradiction, either reduce the cost of pallet production, or through collaborative education and clear rules to improve the recovery rate and reduce the cost of loss.

Because of untimely recovery or return, pallets are occupied by downstream customers for a long period of time, and the low pallet turnover rate leads to insufficient turnover pallet volume, and they are asked to continuously increase pallet investment. Typically, the average pallet usage cycle in the petrochemical supply chain is around 45 days, which includes the number of days from the production of the petrochemical product to its final use. If the pallets cannot be recovered in time, downstream companies will inevitably divert the *** enjoyment of the pallets to meet their own internal turnover needs, which will greatly reduce the pallet turnover rate and increase the *** enjoyment of the pallet operator's additional cost investment.

The amount of pallets needed in circulation = the total amount of goods corresponding to the demand for pallets / the number of pallet turnover

04 petrochemical enterprises downstream of the prevailing distribution model, dealers in order to protect the privacy of downstream customers or to reduce the pallet conversion as well as to guide the downstream recycling management work, hope that the pallet directly with the goods resold to downstream customers, but the pallet cost can not be too high a markup, or it will affect the products The sales itself, according to market research, plastic pallet packaging cost is not higher than 100 yuan / ton to be easily accepted by dealers and end customers. At present, the domestic raw materials imported from Iran plus the cost of plastic pallets is 150 yuan / a, that is, 100 yuan / ton.

Because of the existence of the above contradictions, so the current domestic petrochemical enterprises automated three-dimensional warehouse + *** enjoy the pallet mode often appears downstream penetration rate is insufficient, with the pallet transportation and inverted plate bulk transportation coexist, *** enjoy the pallet and disposable pallet **** the status quo, increasing the additional management costs, and efficiency enhancement is not thorough enough.

Four, countermeasures and recommendations

In order to solve the *** enjoy the tray above contradictory conflicts, and to promote the three-dimensional library + *** enjoy the pallet model landing, the industry can be used in the standing library tray and the library outside the pallet differentiated management program, specifically in the following two forms:

(a) sub-pallet program

That is, the mother of the mother tray does not go out of the warehouse, library transportation, grasping, identifying are only For the sub-pallet, the sub-pallet sent out to downstream customers for pallet transportation with pallets. The sub-pallet technical standard requirements are relatively low, thus the cost is relatively low, and at the same time to ensure that the sub-pallet and the mother pallet in the internal closed-loop operation of the library, to reduce the downstream non-standard operation of the loss. This program has the following disadvantages: 1. Increased pallet usage; 2. Loss of warehouse capacity due to reserving space for additional sub-pallets. At the same time, the advantages are as follows: the sub-pallets used externally can be either *** enjoy pallets or disposable wooden pallets, with space for entry and exit.

(2) inverted plate program

That is, in the vertical warehouse out of the mouth of the installation of pallet flipping equipment, through the flipping equipment, the warehouse pallet will be switched to the warehouse outside the **** enjoy the pallet, so as to avoid the warehouse pallet out of the internal system, to reduce the loss. This program requires additional installation of inverted pallet flipping equipment in the out-of-storage area, increasing facility investment and space occupation. At the same time, the advantages are as follows: 1, saving the amount of pallets; 2, you can choose to push the puller for labor-free loading and unloading transformation, compatible with the pallet-free labor-free loading and unloading mode, but the downstream still need to be manually operated.

The automated three-dimensional warehouse construction is about to plan up the pallet operation mode at the early stage. As the petrochemical industry automated three-dimensional warehouse for the warehouse core facilities, investment is large, the tray is just as the core auxiliary equipment, the proportion of investment is relatively small, but very important, the relationship between the flow of goods to storage efficiency and normal operation of transportation with the tray. Therefore, in the three-dimensional library design at the beginning of the pallet operation mode and into the overall planning. This requires that the three-dimensional warehouse integrators have a strong overall planning, layout and program design capabilities, the entire supply chain operations and pallet operations have a certain understanding. At the same time, to y understand the petrochemical industry within the enterprise sales, storage and other logistics scenarios, in advance of the hardware configuration on the planning.

In the petrochemical enterprises in the three-dimensional warehouse on the pallet of the high standard requirements and the supply chain downstream of the pallet use of poor working conditions under the contradiction, in order to avoid a large amount of redundant waste of resources, petrochemical companies themselves in the planning of logistics systems or three-dimensional library construction of the early stage, the need for pallet operation program, automated inverted pallet inverted plate equipment or mother and father of the pallet program into the overall planning to achieve the library of pallets within the specialized internal cycle management, external Pallet differentiated management of the external cycle, so as to avoid the delivery of the three-dimensional library after the operation period of the tray operation dilemma.

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