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Supply Chain Logistics/cross_docking_flow_through.md

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+# Cross-Docking & Flow-Through Operations
+**Document ID:** SC-XD-003 | **Version:** 2.9 | **Owner:** Sr. Director DC Ops
+**Effective:** 2025-03-01 | **Review Cycle:** Annual
+
+## 1. Purpose
+Standardizes cross-docking and flow-through procedures to minimize
+touches, reduce dwell time, and accelerate store replenishment.
+
+## 2. Definitions
+- **Cross-dock:** Inbound freight transferred directly to outbound
+  trailers without putaway. Touch count = 1.
+- **Flow-through:** Freight moves through DC with minimal handling and
+  no long-term storage (dwell ≤ 12 hrs).
+- **Traditional:** Freight received into storage, picked later.
+
+## 3. When to Cross-Dock
+Cross-docking is mandatory when ALL of the following hold:
+1. SKU is on a **pre-distributed** or **allocation-driven** PO.
+2. Store demand is confirmed and static (no forecast variance > 10%).
+3. Inbound and outbound trailers can be co-scheduled within 4 hrs.
+4. Product has ≥ 30-day shelf life or is non-perishable.
+
+## 4. Cross-Dock Scheduling
+| Window | Inbound Cutoff | Outbound Departure |
+|---|---|---|
+| AM wave | 22:00 prior day | 06:00 |
+| Midday wave | 04:00 | 12:00 |
+| PM wave | 10:00 | 18:00 |
+| Night wave | 14:00 | 23:00 |
+
+Scheduling rule: **Outbound trailer must be staged and sealed within
+90 minutes** of inbound unload completion.
+
+## 5. Yard Management
+- Trailer dwell target: **≤ 3 hours** for cross-dock, **≤ 12 hours** for
+  flow-through.
+- Yard checks performed every **4 hours**; trailer locations logged in YMS.
+- Reefer trailers must maintain **continuous temperature telemetry**;
+  deviations trigger immediate QA notification.
+
+## 6. Pallet & Case Flow
+1. Inbound trailer unloaded in **store-route sequence**.
+2. Cases scanned at **dock door portal** to confirm routing label.
+3. Conveyor or forklift transfers to outbound lane.
+4. Outbound load built in **reverse-stop order**.
+5. Quality check: 1 pallet per trailer audited for label accuracy.
+
+## 7. Quality & Exception Handling
+| Exception | Action | Owner |
+|---|---|---|
+| Mis-routed case | Re-label and re-stage | Flow Coordinator |
+| Damaged pallet | Repack or reject | QC Associate |
+| Temp deviation | Quarantine + QA | Food Safety |
+| Missing case | File OS&D within 2 hrs | Inventory Control |
+| Trailer mismatch | Hold load, escalate | Shift Manager |
+
+## 8. KPIs
+| KPI | Target |
+|---|---|
+| Cross-dock % of total volume | ≥ 60% |
+| Dwell time (cross-dock) | ≤ 3 hrs |
+| Dwell time (flow-through) | ≤ 12 hrs |
+| Touch count per case | ≤ 1.4 |
+| Mis-route rate | ≤ 0.15% |
+
+## 9. Cost Impact
+Cross-docking reduces handling cost by **~$0.18/case** and shortens
+DC-to-store lead time by **6–10 hours** vs. traditional putaway.
+
+## 10. Escalation
+- Real-time: Flow Coordinator → Shift Manager
+- Network: DC GM → Regional Director (within 2 hrs)