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In recent years, with the rising cost of manpower, land and other factors, the upgrading of warehousing logistics in China petrochemical enterprises has been accelerated, and the demand for automated three-dimensional warehouse construction has exploded. Some large petrochemical enterprises have established intelligent logistics systems covering the whole process of packaging, palletizing, film covering, warehousing, storage, distribution and loading and unloading vehicles. In the whole process, standard pallets are used as storage and transportation units, measurement units and information units for consistent intermodal transportation, thus improving the overall supply chain management efficiency, reducing logistics costs and enhancing product competitiveness.
The full-chain-supported transportation operation centered on the automated three-dimensional warehouse is highly dependent on the standardization level of pallets. At the same time, under the background of dual carbon, petrochemical enterprises pay more attention to the sustainable green circulation logistics mode, and the realization of * * * support tray instead of disposable packaging just meets this demand.
Starting from the present situation of pallet sharing operation, this paper probes into and analyzes the problems, causes and solutions encountered in actual pallet sharing operation under the automatic three-dimensional warehouse and pallet sharing mode in petrochemical enterprises.
First, the background
The era of flat warehouse in petrochemical enterprises is gradually declining.
1, rising labor costs
Historically, due to the abundant labor force in China at that time, petrochemical plants needed to solve the employment placement problem on the spot while land acquisition and construction, and the labor cost was low, so petrochemical enterprises mostly used flat warehouses. Manual loading and unloading+forklift operation can basically meet the warehousing and logistics needs of petrochemical enterprises in this period. However, with the aging population in China, the labor cost has risen sharply, and there are fewer and fewer low-end employment groups willing to engage in heavy manual labor. Petrochemical enterprises generally realize that the traditional storage path of building a flat warehouse and relying on a large number of manual loading and unloading operations is no longer feasible.
2. The cost of land has risen.
With the initial formation of world-class refining and chemical bases of large petrochemical enterprises, the production is developing to intensive and large-scale, the production capacity of petrochemical enterprises is greatly improved, and millions of tons of solid product production devices abound. In the past, solid products were stored in the form of pallet stacking, and the storage efficiency of 2 ~ 3 layers of product stacking was low, so the storage form of liquidation must rely on large-scale land resources. Faced with limited land area and rising land cost, petrochemical enterprises tend to use limited land resources for production, resulting in more and more intensive storage land.
3. The demand for refined management is getting higher and higher.
With the improvement of China's economic level and consumption level, downstream customers' demand for petrochemical products has changed from single category and low-end products to diversified and high-end products. The demand of individual customers is increasing, and the requirements of downstream customers for product appearance and timeliness are also increasing. The market competition of petrochemical products is quite fierce. In order to better meet the needs of customers, petrochemical enterprises continue to enrich product categories, and product brands have increased from five or six to hundreds. The storage location of traditional plane library is assigned manually, and it is managed by traditional methods such as making records, inserting brands and labeling. With the increase of product brands, it is necessary to stack products of multiple brands on a stack, which makes the original manual management form with low efficiency and high error rate difficult to cope with; The upper pallet in the warehouse is in direct contact with the lower products, which has poor stability and is easy to collapse. When the forklift piles the upper products, the pallet is easy to cut the packaging of the lower products. Manual forklifts are used to stack products in warehouses. Because warehouses are mostly concrete floors, a large amount of dust and particles emitted by the tail gas during forklift operation are adsorbed on the product packaging bags, which affects the packaging appearance, employee health, downstream product quality and corporate image.
Second, the current situation
Automatic three-dimensional warehouse in petrochemical enterprises+* * * enjoy pallets-the era of supporting transportation is accelerating.
1. Operation Process of Stereo Library
The products pass through the automatic packaging and palletizing production line, and the bagged products are palletized on the tray by the beam high-position palletizer and covered by the automatic laminating machine. Put in storage, send it to the storage crossing of the automatic three-dimensional warehouse through the round shuttle car/conveyor line, and carry it to the designated storage space of the warehouse by the high stacker. In the warehousing verification, the pallet information carrier uses RFID technology to record the information of palletized products in the packaging and palletizing process, and match it with the information of WMS, so that the successfully matched products can be put into storage. Conversely, the same is true for outbound. Loading and unloading trucks, for the products shipped out of the warehouse, generally use the form of "manual+forklift" to transport the products to the designated vehicles, or use unmanned loaders for automatic loading.
Automated three-dimensional warehouse has the advantages of high land utilization rate, high degree of automation, high degree of informatization and low labor cost, and realizes the automatic operation and information management of products from automatic packaging to warehousing, storage and delivery. The use of automated three-dimensional warehouse storage is gradually replacing the traditional storage mode, meeting the needs of the development of petrochemical industry, helping enterprises to improve management and service, and realizing the intelligent and automated upgrading of warehousing logistics. Therefore, it is an inevitable trend for the industry to adopt intelligent three-dimensional warehouse to realize automatic logistics operations such as handling and storage of chemical products.
Except for small petrochemical enterprises with less production facilities and annual output below 300,000 tons, most large petrochemical enterprises in China will adopt automatic three-dimensional warehouse in new project construction, and the construction of automatic three-dimensional warehouse in petrochemical industry has entered an outbreak period and begun to take shape. Large petrochemical enterprises such as Quanzhou Sinochem, Zhenhai Refining & Chemical, Zhongke Refining & Chemical, Sino-Korean Petrochemical, Yangzi Petrochemical and Guangdong Petrochemical took the lead in realizing the construction of the whole-process intelligent logistics system, which had a lot of repercussions in the industry.
2. Supported transportation has become an inevitable choice for petrochemical enterprises in the era of automated warehouse.
The traditional way is based on the optimization of internal logistics operation in order to reduce logistics costs. From the perspective of the whole supply chain, it is an inevitable choice to reduce logistics costs and improve efficiency by improving the level of logistics standardization, increasing the turnover rate of inventory or logistics facilities and reducing the number of manual transactions.
Under the background of three-dimensional warehouse construction, the logistics operation of petrochemical enterprises is more systematic and integrated, and the management concept has also changed from logistics to SCM. Traditional logistics management emphasizes the integration of all logistics links within enterprises, while supply chain management pursues the logistics integration of all chain enterprises in the process of product circulation, including the overall logistics cost of intermediate dealers and end customers. The concept of supply chain management can be realized by the consistent consignment transportation between upstream and downstream, which can improve the efficiency of upstream and downstream connection, improve the turnover rate and reduce the cargo damage and logistics cost.
3.* * * Sharing pallets is the best way to realize the consistency of pallet transportation.
* * * Enjoy the combined upstream and downstream transportation of pallets to support the transportation scheme consistent with pallets. In the past, the industry generally tended to use the way of unpacking and loading transportation to obtain a higher loading rate; There is still a lack of standardization of pallet settlement in upstream and downstream enterprises, and there are many manufacturers and downstream users, and there is a lack of unified planning of pallet form and circulation and recycling process. In recent years, with the rising of labor cost and land cost, the comprehensive construction and operation of automated three-dimensional warehouse and supporting transportation has obvious cost advantages, and it is easy to form a high product service stickiness for downstream customers. The transportation mode of three-dimensional warehouse+* * pallet support has been widely used in petrochemical enterprises. Driven by PetroChina, Sinopec, China Shipping Shell and Wanhua, some private petrochemical enterprises are gradually joining. The emergence of third-party professional pallet operation service providers has solved the problems of pallet asset management, recycling, cross-enterprise settlement and clean maintenance after consignment and transportation. Moreover, China's efforts to control the overload of freight vehicles have been increasing, and it is difficult to realize the way of overloading and profit through palletizing transportation. Palletized transportation began to be accepted by petrochemical enterprises, which provided convenient conditions for the application of automatic three-dimensional warehouse and the transportation mode consistent with pallet.
Disposable pallets and recycling * * * enjoy the comprehensive survey score of pallets.
Third, the contradiction of automatic stereoscopic library+* * shared tray mode operation
Requirements and characteristics of automatic three-dimensional pallet
The automation warehouse of petrochemical enterprises requires very high standardization of pallets, otherwise it will easily lead to production accidents, which are embodied in the following characteristics:
① Large dose
A vertical warehouse usually has 20,000 to 50,000 warehouses. The flow of pallets in and out of the warehouse is usually more than 200 pallets per hour, and the daily replenishment of pallets is usually more than 2,000.
(2) Concentration of warehousing operations.
It belongs to "big in and big out" with obvious peaks and valleys. There is a general shortage of spare pallets in petrochemical storage areas, which requires pallet service providers to provide JIT mode for flexible replenishment.
③ The automation operation of warehouse requires extremely high reliability of pallets.
Its pallet test standard is much higher than the performance requirements of GB/T3578 1-20 17 "Plastic Flat Pallets for Pallets * * *". According to calculation, the production cost of plastic pallets that can meet the requirements of vertical storage is generally above that of 400 yuan. Petrochemical production is a continuous process industry, and it is absolutely not allowed to stop production halfway. As the last link of continuous process industry, intelligent three-dimensional warehouse is not allowed to stop production due to operational failure in the upstream.
Take petrochemical silo as an example
The technical requirements for vertical warehouse pallets are as follows:
And GB/T3578 1-20 17 plastic flat pallet has the following bearing capacity requirements for pallet * * *:
2. Contradictions and problems in China's pallet operation * * * China's pallet operation is in the primary stage of industry development. Different from the mature developed economies abroad, the habit of pallet lease management has been generally formed, that is, pallet users have special areas to be recycled, store pallets in different categories, and have special personnel to confirm warehousing, check inventory, return pallet assets and reconcile expenses. Therefore, at present, there are still the following contradictions in the application of+* * * tray mode in domestic three-dimensional libraries.
* * * Enjoy the contradictions in pallet operation at this stage.
0 1 The downstream scene is complex, the operation is not standardized, and the damage rate of the back brace is high. * * The sharing tray needs to undergo strict screening (such as whether the supporting structure is damaged, whether the RFID is lost, whether the lamp position is damaged, whether the burr is protruding, and whether the steel pipe is corroded). ), otherwise it will be difficult to meet the requirements of direct use of the three-dimensional warehouse, resulting in abnormal storage after palletizing and high storage exit rate, leading to manual disassembly and reorganization.
There are many downstream customers. Under the general distribution mode of petrochemical industry, the pallet circulation process is complex and the pallet loss rate is high. However, the production cost of vertical warehouse pallet is higher, and the price is usually above 400 yuan/set. Once a high proportion is lost, it will cause great sustained losses to the pallet owner. Under the condition that there is no difference blindness (that is, the responsibility of pallet loss and damage cannot be actually passed on to pallet users), the pallet loss rate even exceeds 10%. Therefore, without considering other operating costs, the loss cost of single pallet allocated to pallet operation only exceeds that of 40 yuan. Obviously, this is not a healthy business model. If the loss cost is borne by the downstream pallet users, it is obviously unacceptable to the downstream customers, and it is also unsustainable for the * * * pallet operators to bear it. To solve this contradiction, we should either reduce the cost of pallet production or clarify the rules through collaborative education, improve the recovery rate and reduce the cost loss.
Due to untimely recovery or return, pallets are occupied by downstream customers for a long time, and the turnover rate of pallets is low, which leads to insufficient turnover pallets, so it is necessary to continuously increase pallet investment. Generally speaking, the average service life of pallets in petrochemical products supply chain is about 45 days, including the days from production to final use of petrochemical products. If the pallet can't be recycled in time, the downstream enterprises will inevitably use the pallet for other purposes to meet their internal turnover demand, which will greatly reduce the pallet turnover rate and increase the extra cost of the pallet operator.
Number of pallets required for circulation = pallet demand corresponding to total goods/pallet circulation times.
There is a general distribution mode in the downstream of petrochemical enterprises. In order to protect the privacy of downstream customers, reduce pallet conversion and guide downstream recycling management, dealers want to resell pallets directly to downstream customers, but the pallet fee cannot be increased too much, otherwise it will affect the sales of the products themselves. According to market research, the packaging cost of plastic pallets is not higher than 65,438+000 yuan/ton, which is easily accepted by dealers and end customers. At present, the cost of raw materials and plastic pallets imported from Iran is 150 yuan/piece, that is, 100 yuan/ton.
Due to the above contradictions, the pallet sharing mode of automated warehouse in domestic petrochemical enterprises often lacks downstream permeability, pallet transportation and bulk cargo transportation coexist, pallet sharing and disposable pallet coexist, which increases the additional management cost and the efficiency improvement is not thorough enough.
Four. Countermeasures and suggestions
In order to solve the contradiction above the * * * shared pallet and promote the landing of the three-dimensional warehouse+* * shared pallet model, the industry can adopt the differentiated management scheme of vertical warehouse pallet and outside warehouse pallet, which has the following two forms:
(1) mother-child support plan
That is, the mother pallet does not leave the warehouse, and the transportation, grabbing and identification in the warehouse are only for the sub-pallets, and the sub-pallets are sent to downstream customers for pallet transportation. The technical standard of the auxiliary tray is relatively low, so the cost is relatively low. At the same time, it ensures the closed-loop operation of the vertical warehouse sub-tray, and reduces the loss of downstream irregular operation. This scheme has the following disadvantages: 1, the consumption of pallets increases; 2. Because extra sub-tray space is reserved, the storage capacity is lost. At the same time, the advantages are as follows: the external sub-tray can choose * * * enjoyment tray or disposable wooden tray, which has room for advance and retreat.
(2) Overturning scheme
That is, a tray turnover device is installed at the exit of the vertical warehouse. The tray in the warehouse is switched to enjoy the tray outside the warehouse through the turnover device, which prevents the tray in the warehouse from flowing out of the internal system and reduces the loss. In this scheme, it is necessary to install additional inversion equipment in the reservoir area to increase the investment in facilities and space occupation. At the same time, the advantages are as follows: 1, saving pallet consumption; 2. Manual loading and unloading transformation can choose push-pull device, which is compatible with pallet-free manual loading and unloading mode, but manual operation is still needed downstream.
The pallet operation mode will be planned in the early stage of the construction of automatic three-dimensional library. As the automated three-dimensional warehouse in petrochemical industry is the core facility of the warehouse, the investment is large, and the pallet is only the core auxiliary equipment, so the investment ratio is relatively small, but it is very important, which is related to the circulation efficiency of stored goods and the normal operation of supporting transportation. Therefore, in the initial stage of the design of the three-dimensional library, it is necessary to bring the pallet operation mode into the overall planning. This requires warehouse integrators to have strong overall planning, layout and scheme design capabilities, and have a certain understanding of the whole supply chain operation and pallet operation. At the same time, it is necessary to deeply understand the logistics scenes such as sales and warehousing of petrochemical enterprises, and plan the hardware configuration in advance.
Under the contradiction between the high standard requirements for pallets in petrochemical enterprises' warehouses and the poor use conditions of pallets in the downstream supply chain, in order to avoid a lot of redundant waste of resources, petrochemical enterprises themselves need to incorporate the pallet operation scheme, automatic pallet dumping equipment or sub-mother pallet scheme into the overall planning at the initial stage of planning the logistics system or warehouse construction, so as to realize the specialized internal circulation management of pallets in the warehouse and the differentiated management of external pallets, and avoid the dilemma of pallet operation during the operation after delivery of the warehouse.
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