storage calculation model & capacity utilization

AB20.04 STORAGE CALCULATION MODEL & CAPACITYUTILIZATION RATEUTILIZATION RATE

Fruit Cold Store

LFCLogistics Center in Thiva501.AB20.04 STORAGE CALCULATION MODEL & CAPACITY UTILIZATION RATE.Rev.1

O t b 12 2010

CLIENT:

PROJECT:

DOCUMENTCODE:October 12, 2010

I. Manolas / Technical DirectorSigner:

Checked:

Stock (Drive in) Stock (Drive in)( ) Stock (Drive in)

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1. Receiving Loading Area 2. Receiving Loading Area 3. Receiving Loading Area 4. Receiving Loading Area

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TITLE:e.00401-AB20.04.01-CONTENS:WAREHOUSE OPERATION STUDY-PROJECT MANAGER:MANOLAS I.-12/10/2010

CLIENT:CP26 - Training and Operation & Maintenance Manuals

WAREHOUSE OPERATION STUDY

CLIENT:PROJECT:

DELIVERABLESWAREHOUSE OPERATION STUDYMANOLAS I.

e 00401 AB20 04 01

TITLE:PROJECTMANAGER:

DATE:DOCUMENT CODE

12/10/2010e.00401-AB20.04.01DOCUMENTCODE:

CONTENTS DATELEADDESIGNER01.02.03

BASIC DATA OF THE WAREHOUSEPRODUCT HANDLING & CALCULATION DATATIME CALCULATIONS OF GOODS TRANSFER PROCESSES

MANOLAS I.MANOLAS I.MANOLAS I

12/10/201012/10/201012/10/201003.

04.05.06. OPERATING DATA FOR ELECTRICAL PALLETE TRUCKS

TIME CALCULATIONS OF GOODS TRANSFER PROCESSESSUMMARY DATA REVIEWWEEKLY DISTRIBUTION OF WORK

MANOLAS I.MANOLAS I.

12/10/201012/10/2010

MANOLAS I. 12/10/2010MANOLAS I. 12/10/201006. OPERATING DATA FOR ELECTRICAL PALLETE TRUCKS

07. OPERATING DATA FOR REACH TRUCKS08. OPERATING DATA FOR ELECTRIC PEDESTRIAN TRUCKS09. OPERATING DATA FOR WAREHOUSE STAFF

MANOLAS I. 12/10/2010MANOLAS I. 12/10/2010MANOLAS I. 12/10/2010MANOLAS I. 12/10/2010

10. COSTS SUMMARIES

MANOLAS I. 12/10/2010

TITLE:e.00401-AB20.04.01/01./WAREHOUSE OPERATION STUDY/CONTENTS:BASIC DATA OF THE WAREHOUSE/LEADDESIGNER:MANOLAS I. /DATE:12/10/2010

1.BASIC DATA OF THE WAREHOUSE1.1.GENERAL BUILDING AND STORAGE DATA

Stock (Drive in) Stock (Drive in)

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rn2 Hi h d t 3 Le el 540 plts 1 080 plts 785 22 High dens storage rooms 3 Level 540 plts 1.080 plts 785 m2

2 High dens storage rooms 3 Level 420 plts 840 plts 629 m2

8 Low dens storage rooms 3 Level 198 plts 1.584 plts 1904 m2

2 Low dens storage rooms 3 Level 108 plts 216 plts 240 m2g p p4 Banana ripening rooms 2 Level 20 plts 80 plts 99 m2

18 Rooms total 3.800 plts 3.658 m2

2And order preparation packing room and loading 2.493 m2

The total area is 6.480 m2

1.2. WAREHOUSE'S ANNUAL HANDLING OF GOODS

Citrus Fruits 01 23 500 pltsCitrus Fruits 01 23.500 pltsKiwis 02 1.000 plts

Apples 03 7.500 pltsPears 04 4.500 plts

Potatoes 05 8.000 pltsOnions - Garlic 06 3.500 plts

Tomatoes 07 2.000 pltsCabbages Peppers 08 7 000 pltsCabbages - Peppers 08 7.000 plts

Bananas 09 500 pltsFruits 10 1.000 plts

Dry bulk 11 500 pltsyRest prod. 12 1.000 plts

60.000 plts

TITLE:e.00401-AB20.04.01/01./WAREHOUSE OPERATION STUDY/CONTENTS:BASIC DATA OF THE WAREHOUSE/LEADDESIGNER:MANOLAS I. /DATE:12/10/2010

1.BASIC DATA OF THE WAREHOUSE

1.3. STORAGE DATA

Citr s Fr its 01 4 877 plts 41 da s

With an average residencetime

At the High Dens Storage

Citrus Fruits 01 4.877 plts 41 daysApples 03 3.112 plts 30 daysPears 04 2.291 plts 33 days

Potatoes 05 1.832 plts 37 daysO i G li 06 1 141 lt 33 dOnions - Garlic 06 1.141 plts 33 days

13.254 plts 36 days

Citrus Fruits (out) 8.030 plts 41 daysCitrus Fruits (out) 8.030 plts 41 days21.284 plts

Note 1Hi h d t i d fi d th di t l t d ti h th fi f ff t d tl b l t bl k 15High dense storage is defined as the medium to long storage duration when the fi-fo effected partly by lots - block over 15 pallets

Citrus Fruits 01 7.784 plts 16 days 14 days

Indicated values of 2001(High & Low Density)

With an average residence time

At the Low dens storage

Kiwis 02 735 plts 7 days 9 daysApples 03 3.224 plts 21 days 23 daysPears 04 1.623 plts 15 days 19 days

Potatoes 05 4.532 plts 14 days 13 daysp y yOnions - Garlic 06 1.734 plts 11 days 8 days

Tomatoes 07 1.470 plts 6 days 6 daysCabbages - Peppers 08 5.144 plts 6 days 6 days

Bananas 09 367 plts 0 days 1 daysBananas 09 367 plts 0 days 1 daysFruits 10 735 plts 5 days 9 days

Dry bulk 11 367 plts 4 days 15 daysRest prod. 12 735 plts 20 days 32 days

28 448 lt 17 d 14 d28.448 plts 17 days 14 daysNote 2Low dense storage is defined as the short-term storage duration when the fi-fo process is implementing totaly

Note 3It is assumed that the handlig of all the storage volume (and the external storage) is implementing through the Order preparation space of the warehouse centre.

2.PRODUCT HANDLING & CALCULATION DATA2.1. OPERATING TIME OF WAREHOUSE

TITLE:e.00401-AB20.04.01/02./WAREHOUSE OPERATION STUDY/CONTENTS:PRODUCT HANDLING & CALCULATION DATA/LEAD DESIGNER:MANOLAS I. /DATE:12/10/2010

The operating time of the Center is divided into 48 periods (4 / month). The number of days per period are:

8 8 7 8 7 7 7 8 8 8 7 8 8 7 7 8 8 8 7 7 8 8 7 7 8 8 8 7 8 8 8 7 7 8 8 7 8 8 8 8 7 8 7 8 8 8 7 6Sept Oct Nov DecMay June July AugJan Feb March April

The center manages the stocks with 4 general categories of services.Note 4

A) For storage stocks (dense and short)B) For Cross Docking StocksC) The Stocks to TranshipmentD) B t k ( hi h ill b t f d t th i i )In the initial quantities of goods extra quantities transported Banana are added

2.2. MAXIMUM DAILY INCOMING GOODS HANDLING OF THE CENTER

D) Banana stock (which will be transferred to the ripening rooms)

The max. daily handling of the Center (max/Period) Incoming goods is:

Annual Handling (indicative values 2010)

2010 TRAN. ^To storage 70% 41.702 66% - 192 260 325 388 449 506 562 614 664 712 757 799 839 877 911 944 973 1000 1025 1047 1066 1083 1098 1109 1118 1125 1129 1131 1130 1126 1120 1111 1100 1086 1070 1051 1029 1005 979 949 918 883 847 807 765 721 674 624

T Hi h d t 22% 13 2 4 21% 0% 63 68 9 111 103 119 142 180 19 21 192 228 248 261 282 334 348 332 286 298 316 382 334 391 436 42 41 3 6 399 386 3 4 320 313 3 2 346 301 333 31 29 2 8 231 248 218 2 266 286 269 309

DecNovJune July Aug Sept OctJan Feb March April May

To High dense storage 22% 13.254 21% 0% 63 68 97 111 103 119 142 180 195 215 192 228 248 261 282 334 348 332 286 298 316 382 334 391 436 425 415 356 399 386 374 320 313 352 346 301 333 315 297 278 231 248 218 257 266 286 269 309 To Low Dense storage 47% 28.448 45% 0% 129 192 229 277 346 387 420 434 469 497 565 572 592 616 629 610 625 668 739 749 750 702 763 718 683 700 715 775 731 740 746 792 787 735 724 749 696 690 682 672 687 635 629 550 499 434 405 315

Transhipment 17% 10.458 17% 0% 28 37 47 58 69 80 92 104 117 129 142 155 168 181 193 206 218 230 242 253 263 273 283 291 299 306 313 318 322 325 327 327 327 325 321 316 310 302 292 280 267 251 234 215 193 170 144 116Cross Docking 13% 7.840 12% 0% 55 77 97 115 131 146 159 170 180 189 197 203 208 211 214 216 217 216 216 214 212 209 205 201 197 192 188 182 177 172 166 161 156 151 146 142 137 134 131 128 126 125 125 125 126 129 132 136

Unloading (Plts in) 100% 60.000 100% 0% 276 374 469 561 648 732 812 889 961 1030 1096 1157 1215 1269 1319 1365 1408 1447 1482 1514 1541 1565 1586 1602 1615 1624 1629 1631 1629 1623 1613 1600 1583 1562 1537 1509 1476 1441 1401 1358 1311 1260 1205 1147 1085 1019 950 876U l di B (Plt i ) 5%Unloading Bananas (Plts in) 0% 3.000 5% 5% 14 19 23 28 32 37 41 44 48 52 55 58 61 63 66 68 70 72 74 76 77 78 79 80 81 81 81 82 81 81 81 80 79 78 77 75 74 72 70 68 66 63 60 57 54 51 47 44

Unloading (Plts in) 100% 63.000 105% 105% 289 393 493 589 681 769 853 933 1010 1082 1150 1215 1275 1332 1385 1433 1478 1519 1556 1589 1618 1644 1665 1682 1696 1705 1711 1712 1710 1704 1694 1680 1662 1640 1614 1584 1550 1513 1471 1426 1376 1323 1265 1204 1139 1070 997 920

2.3. MAXIMUM DAILY OUTCOMING GOODS HANDLING OF THE CENTER

The max. daily handling of the Center (max/Period) Outcoming goods is:

The units of measurement of the volume of goods is plts (in) & (plts out). These indicators are used to indicate whether the amount described on integer or mixed Note 5

Picking (plts in)

pallets. Mixed pallets typically have smaller volume resulting in the output number of the wood is greater than the input.

Annual Handling (indicative values 2010)

Vol. increase of Plts due Picking 30%

Picking (plts in) 31% 17.767 28% 0% 159 153 148 144 342 340 339 339 340 342 344 348 351 355 360 365 370 375 381 387 392 398 404 409 414 419 424 428 432 435 437 439 440 440 440 438 435 432 427 421 413 405 395 383 370 355 339 321Picking (plts out) 23 097 207 199 192 187 444 442 441 441 442 445 448 452 456 462 468 474 481 488 495 503 510 518 525 532 539 545 551 556 561 565 568 571 572 572 572 569 566 561 555 547 537 526 513 498 481 462 441 417

(indicative values 2010)

June July AugJan Feb March Sept Oct Nov DecApril May

Picking (plts out) - 23.097 - - 207 199 192 187 444 442 441 441 442 445 448 452 456 462 468 474 481 488 495 503 510 518 525 532 539 545 551 556 561 565 568 571 572 572 572 569 566 561 555 547 537 526 513 498 481 462 441 417

Picking from High Dense storage 7% =

- Exit from storage rooms (Plts in)

1.244 16.523and from Low Dense

Total Exit 40% 23.755 38% - 41 111 177 240 123 179 232 282 328 372 412 450 484 516 545 571 594 615 633 649 662 673 682 688 692 694 694 692 687 681 673 663 652 638 624 607 589 569 548 526 503 478 452 425 396 367 337 306(Plts in)

(S. plt.) Exit from High Dense 20% 12.010 19% - 21 56 90 121 62 91 117 142 166 188 208 227 245 261 275 289 300 311 320 328 335 340 345 348 350 351 351 350 348 344 340 335 330 323 315 307 298 288 277 266 254 242 228 215 200 186 170 155(S plt ) Exit from High Dense 20% 11 925 19% - 21 56 89 120 62 90 117 141 165 187 207 226 243 259 273 287 298 309 318 326 333 338 342 345 347 348 348 347 345 342 338 333 327 321 313 305 296 286 275 264 252 240 227 213 199 184 169 154(S. plt.) Exit from High Dense 20% 11.925 19% 21 56 89 120 62 90 117 141 165 187 207 226 243 259 273 287 298 309 318 326 333 338 342 345 347 348 348 347 345 342 338 333 327 321 313 305 296 286 275 264 252 240 227 213 199 184 169 154

Loading (Plts in) 100% 63.000 - 5% 391 482 571 656 737 815 890 961 1029 1094 1155 1212 1266 1317 1364 1408 1448 1485 1519 1549 1576 1599 1619 1635 1648 1657 1663 1666 1665 1661 1653 1642 1628 1610 1588 1564 1535 1504 1468 1430 1388 1343 1294 1241 1186 1127 1064 998Loading only whole 57% 34.213 54% - 69 148 224 298 192 259 324 386 445 501 554 604 652 696 738 777 812 845 875 902 926 947 965 980 992 1001 1007 1009 1009 1006 1000 991 979 963 945 923 899 871 840 806 769 729 686 639 590 537 481 422

Bananas (out) - 3 900 - - 18 24 31 36 42 48 53 58 62 67 71 75 79 82 86 89 92 94 96 98 100 102 103 104 105 106 106 106 106 105 105 104 103 102 100 98 96 94 91 88 85 82 78 75 71 66 62 57Bananas (out) - 3.900 - 18 24 31 36 42 48 53 58 62 67 71 75 79 82 86 89 92 94 96 98 100 102 103 104 105 106 106 106 106 105 105 104 103 102 100 98 96 94 91 88 85 82 78 75 71 66 62 57Loading only mixed plts. - 33.289 - - 279 299 318 337 614 631 647 663 677 691 703 715 726 737 746 755 762 769 775 781 785 789 792 794 795 795 795 793 791 788 785 780 775 768 761 753 745 735 725 714 702 689 675 660 645 629 612 594

Loading (Plts in & out) 119% 71.402 - - 366 472 573 671 848 938 1024 1106 1184 1258 1329 1395 1457 1515 1570 1620 1666 1709 1747 1781 1811 1837 1859 1877 1891 1901 1907 1909 1907 1900 1890 1875 1856 1833 1806 1775 1739 1700 1656 1608 1556 1500 1439 1374 1305 1232 1155 1073

2.PRODUCT HANDLING & CALCULATION DATA

TITLE:e.00401-AB20.04.01/02./WAREHOUSE OPERATION STUDY/CONTENTS:PRODUCT HANDLING & CALCULATION DATA/LEAD DESIGNER:MANOLAS I. /DATE:12/10/2010

2.4. INTERNAL GOODS TRASNFER HANDLING OF THE CENTER

The daily internal transfers in the center on transfers concerns stocks from high dense areas to low dense storage areas

Note 6Internal transfers are defined as transfers intended to restructure the stock in order to improve utilization of storage space. Such is the transport of the high dense in low dense storage when the handling of stores leaves remaining lots in the dense blocks smaller than i pallets

- Average batch product handling 10 plts at the high dense k

in low dense storage when the handling of stores leaves remaining lots in the dense blocks smaller than i pallets.

- Average rest of Block i= 5

Internal trasfer 10% 6.005 10% 10 28 45 61 31 45 59 71 83 94 104 114 122 130 138 144 150 155 160 164 167 170 172 174 175 175 175 175 174 172 170 168 165 161 158 153 149 144 139 133 127 121 114 107 100 93 85 77Nov Dec

pallets

June July Aug Sept OctJan Feb March April May

Note 7Internal transfers also define the suppling of the Banana ripening rooms

Internal transfer ripening rooms 3.000 14 19 23 28 32 37 41 44 48 52 55 58 61 63 66 68 70 72 74 76 77 78 79 80 81 81 81 82 81 81 81 80 79 78 77 75 74 72 70 68 66 63 60 57 54 51 47 44DecJan Feb March April May June July Aug Sept Oct Nov

3. TIME CALCULATIONS OF GOODS TRANSFER PROCESSES3.1. OPERATING TIME OF ELECTRO PALLET TRUCKS DURING IN - OUT OF GOODS

The average distance per room of internal transfer vehicles is:

In - Out of Goods

TITLE:e.00401-AB20.04.01/03./WAREHOUSE OPERATION STUDY/CONTENTS:TIME CALCULATIONS OF GOODS TRANSFER PROCESSES/LEAD DESIGNER:MANOLAS I. /DATE:12/10/2010

Totally average trip distance In Outo

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Average t L

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Average

A 1 48 47% 23 1 35 5% 1,8 m2 51 53% 27 2 38 40% 15 m3 3 66 40% 264 4 92 15% 145 32 24% 7,86 22 24% 5,27 19 4% 0,88 27 24% 6,59 38 24% 9,110111213

57,2

29,3

distance In-Out

High D. 213,549,6 Low D. 172,8

R

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distance Wi

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distance

Phase A transfer at end line of storage

Phase B transfer to rooms

1415-18

The vehicles are moving with a average speed ( U ) km/hr of U = 6 km/hr = 100 m/min

The vehicles per trip forced into () stops = 8 stops, time loss / stop t1 t1 = 5 sec / stop = 0,1 min

The average opening and closing time for the doors at the cold rooms are (T2) T2 = 0,3 min

The opening of the doors will be done per 10 plts at High dense k 2 plts at Low Dense

The utilization rate of the work is defined at

The complexity rate of work for In - Out is defined at

85%

5%

so:

Average trip time (Elect. Pallet trucks) 3,1 min or 186 sec

Total operating time of Pallet trucks during In - Out of goods

10 13 17 20 23 26 29 32 34 37 39 41 43 45 47 49 50 52 53 54 55 56 57 57 58 58 58 58 58 58 58 57 57 56 55 54 53 52 50 49 47 46 44 42 40 37 35 322 6 9 13 6 9 12 15 17 20 22 24 25 27 29 30 31 32 33 34 35 35 36 36 36 36 36 36 36 36 35 35 34 34 33 32 31 30 29 28 26 25 24 22 21 19 18 16

12 19 26 33 30 35 41 46 51 56 61 65 69 72 76 79 82 84 86 88 90 91 92 93 94 95 95 95 94 94 93 92 91 90 88 86 84 82 79 77 74 71 67 64 60 57 53 49

(in) Hours(out) Hours

El. Plt Truck Hours

July Aug Sept Oct Nov DecJan Feb March April May June

3. TIME CALCULATIONS OF GOODS TRANSFER PROCESSES


3.2. OPERATING TIME OF REACH TRUCKS DURING ARRANGE - RETRIEVE OF PALLETS

at High Dense storage (in) at Low Dense storage (in)

Preparation time (transfer to Buffer, pallete receipe, rack approach) is: T1 = 30 sec / plt = 0,5 min T1 = 20 sec / plt = 0,3 min

Time for pallete placement is: T2 = 40 sec / plt = 0,7 min T2 = 20 sec / plt = 0,3 min

The average batch per room is: i = 10 plts i = 5 plts

at High Dense storage (Out) at Low Dense storage (Out)

Retrieve time (rack approach, pallete receipe and download)is: 'T1 = 40 sec / plt = 0,7 min 'T1 = 20 sec / plt = 0,3 min

Deposition time (transfer to Buffer, pallete deposition) is: 'T2 = 15 sec / plt = 0,3 min 'T2 = 15 sec / plt = 0,3 min

The average batch per room is: 'i = 10 plts 'i = 3 plts

3.3. TRANSFER - SWITCHING TIME

Average trip distance for switching is: = 70 m

The forklifts moving with average speed ( U ) km/hr U = 5 km/hr = 83 m/min

The forklifts per trip forced into () stops = 4 stops

Time loss per stop ( t1 ) t1 = 5 sec / stop = 0,1 min

The average opening and closing time for the doors at the cold rooms are ( T2 ) T2 = 0,3 min (during transfer)


3.4. OPERATING TIME OF ELECTRICAL PALLET TRUCKS

Service Load Ratio between Reach Truck and Electrical Pallet Trucks of the total load

80%

65%

at High Dense storage (in) at Low Dense storage (in)

Preperation time (transfer to Buffer, pallete receipt, rack approaching) is: T1 = 15 sec / plt = 0,3 min T1 = 10 sec / plt = 0,2 min

Time of pallete placement is: T2 = 20 sec / plt = 0,3 min T2 = 10 sec / plt = 0,2 min

at High Dense storage (Out) at Low Dense storage (Out)

Retrieval time (rack approaching, receipt and download of pallete) is: 'T1 = 20 sec / plt = 0,3 min 'T1 = 10 sec / plt = 0,2 min

Time of pallete deposition (transfer to Buffer, pallete depostion) is: 'T2 = 10 sec / plt = 0,2 min 'T2 = 10 sec / plt = 0,2 min

The utilization rate of the work is defined at 85%



so: Total High dense Short term

Average time per pallete for Arrangment (Reach Truck) 1,4 min or 81 sec 1,6 min or 99 sec 1,2 min or 73 sec

Average time per pallete for Retrieval (Reach Truck) 1,3 min or 81 sec 1,3 min or 73 sec 1,4 min or 81 sec

1,4 min or 81 secT t l ti f A t R t i l (R h T k)Total time for Arrangment - Retrieval (Reach Truck)

3 4 5 6 6 7 8 9 10 10 11 12 12 13 13 14 14 15 15 15 15 16 16 16 17 17 17 16 17 17 16 16 16 16 16 15 15 15 14 14 13 13 12 12 11 11 10 101 2 3 4 2 3 3 4 5 5 6 7 7 8 8 8 9 9 9 10 10 10 10 10 10 10 10 10 10 10 10 10 10 9 9 9 9 8 8 8 7 7 7 6 6 5 5 4

3 5 7 9 8 10 11 13 14 16 17 18 19 20 21 22 23 24 24 25 25 26 26 26 27 27 27 27 27 27 26 26 25 25 25 24 24 23 22 21 20 20 19 18 17 16 15 14

Total High dense Short term

Average time per pallete for Arrangment (El. Pallete Truck) 0,5 min or 29 sec 0,7 min or 41 sec 0,4 min or 24 sec

Average time per pallete for Retrieval (El. Pallete Truck) 0,5 min or 29 sec 0,6 min or 24 sec 0,4 min or 24 sec

0 5 min or 29 sec

Arrangment HoursRetrieval Hours

Reach T Hours


0,5 min or 29 secTotal time for Arrangment - Retrieval (El. Pallete Truck)

1 1 1 1 1 1 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 2 2 2 2 2 2 2 20 0 1 1 0 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 1 1 1 1 1 1 1 1

1 1 1 2 2 2 2 3 3 3 3 4 4 4 4 4 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 4 4 4 4 4 4 4 3 3 3 3

3.5. OPERATING TIME DURING THE PROCESSES OF CROSS DOCKING - PICKING - TRANSSHIPMENT

Picking - Cross Docking goods Totally average trip di t Pi kiTotally average trip

di t Mi d P ll too

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Arrangment HoursRetrieval Hours

El. Plt Truck Hours

July August September October November DecemberJan Feb March April May June

Picking Cross Docking goods

A 1 78 5% 3,9 1 50 5% 2,5 m m2 81 2% 1,6 2 20 40% 83 3 48 40% 194 4 78 15% 125 63 23% 146 52 23% 127 30 1% 0,3 m m8 25 23% 5,89 15 23% 3,510111213

41,2

Totally average trip distance Picking

Totally average trip distance

Transshipment41,4

Cross Docki 82,8 Mix Plts 110,4

distance Picking distance Mixed Pallets

Picking 82,5 Mix Plts 82,8

R

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distance Wi

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distance

Phase A transfer to Picking Buffer

Phase B transfer to Loading

1314

15-18



3.6. OPERATING TIME OF REACH TRUCK DURING PICKING

(as previously)so:

Average time per plt (Reach Truck) 1,3 min or 81 sec

3,6 3,4 3,3 3,3 7,7 7,7 7,6 7,7 7,7 7,7 7,8 7,8 7,9 8,0 8,1 8,2 8,3 8,5 8,6 8,7 8,8 9,0 9,1 9,2 9,3 9,5 9,6 9,7 9,7 9,8 9,9 9,9 9,9 9,9 9,9 9,9 9,8 9,7 9,6 9,5 9,3 9,1 8,9 8,6 8,3 8,0 7,6 7,2

3.7. OPERATING TIME OF ELEC. PALLETE TRUCK DURING PICKING AT CYCLE A

The vehicles are moving with a average speed ( U ) km/hr of U = 5 km/hr = 83 m/min

The vehicles per trip forced into () stops = 4 stops, time loss / stop t1 t1 = 5 sec / stop = 0,1 min at cycle

= 2 stops, time loss / stop t1 t1 = 5 sec / stop = 0,1 min at cycle

= 5 stops, time loss / stop t1 t1 = 5 sec / stop = 0,1 min at transshipment

The average opening and closing time for the doors at the cold rooms are (T2) T2 = 0,3 min

Sept Oct Nov DecReach T Hours

Jan Feb March April May June July Aug

g p g g ( ) ,

The opening of the doors will be done per 1 plts


so

Average time per plt (in) (El. Plt Truck) 1,9 min or 117 sec

5 5 5 5 11 11 11 11 11 11 11 11 11 12 12 12 12 12 12 13 13 13 13 13 13 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14 13 13 13 12 12 12 11 10

3.8. OPERATING TIME OF ELEC. PALLETE TRUCK DURING TOTAL PICKING AT CYCLE B

85%

Plt Truck (A) HoursJuly Aug Sept Oct Nov DecJan Feb March April May June

(respectively)so:Average time per plt (out) (El. Plt Truck) 1,4 min or 82 sec

6 7 7 8 14 14 15 15 15 16 16 16 17 17 17 17 17 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 18 17 17 17 17 17 16 16 16 16 15 15 15 14 14 14

3.9. OPERATING TIME OF ELEC. PALLETE TRUCK DURING CROSS DOCKING AT CYCLE B

(as previously)so:Average time per plt (in) (El. Plt Truck) 1,4 min or 82 sec

Sept Oct Nov DecPlt Truck (B) Hours


1 2 2 3 3 3 4 4 4 4 4 5 5 5 5 5 5 5 5 5 5 5 5 5 4 4 4 4 4 4 4 4 4 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3Plt Truck (B) HoursJuly Aug Sept Oct Nov DecJan Feb March April May June



3.10. OPERATING TIME OF ELEC. PALLETE TRUCK DURING TRANSSHIPMENT AT CYCLE B

(as previously)so:

Average time per plt (in) (El. Plt Truck) 2,0 min or 123 sec

1 1 2 2 2 3 3 4 4 4 5 5 6 6 7 7 7 8 8 9 9 9 10 10 10 10 11 11 11 11 11 11 11 11 11 11 11 10 10 10 9 9 8 7 7 6 5 4

3.11. OPERATING TIME OF ELEC. PALLETE TRUCKS DURING THE ROTATION CYCLE OF PICKING - CROSS DOCKING INSIDE THE PICKING ZONE

The Picking - Cross Docking cycle is: = 95 m

The vehicles are moving with a average speed ( U ) km/hr of U = 4 km / hr = 67 m / min


During Cross Docking

85%

Sept Oct Nov DecPlt Truck (B) Hours


The Mix plt follow inside the Picking zone a trip of 3 deposition points with time loss 60 sec / point = 1,0 min

Also is forced to 4 safety stops with time loss 5 sec / stop = 0,1 min

Weighting for of the goods is done, with a distance 20 m / weighting with time loss 60 sec = 1,0 min (for stops, deposition - retrieval at the weighter and note indications)

During Picking

The Mix plt follow inside the Picking zone a trip of 5 picking points with time loss 40 sec / point = 0,7 min

Also is forced to 4 safety stops with time loss 5 sec / stop = 0,1 min

Weighting for of the goods is done, with a distance 20 m / weighting with time loss 50 sec = 0,8 min (for stops, deposition - retrieval at the weighter and note indications)

Paletizing for of the goods is done with a average time 30 sec = 0 5 min

100%

50%

95%Paletizing for of the goods is done, with a average time 30 sec = 0,5 min

so:Average time per plt (in) (Cross Docking) (for breaking) 10 min or 611 sec average (for the sum of the plts)

9 13 16 20 22 25 27 29 31 32 33 34 35 36 36 37 37 37 37 36 36 35 35 34 33 33 32 31 30 29 28 27 26 26 25 24 23 23 22 22 21 21 21 21 21 22 22 23

Average time per plt (out) (Picking) (for composition) 9,9 min or 593 sec average (for the sum of the plts)

46 49 52 55 101 104 107 109 112 114 116 118 120 121 123 124 126 127 128 129 129 130 130 131 131 131 131 131 130 130 129 128 128 127 125 124 123 121 119 118 116 113 111 109 106 104 101 98

95%

Sept Oct Nov DecEl. Pal.(p z) Hours

El. Pal.(p z) Hours





3.12. OPERATING TIME DURING THE PROCESS OF RE-DEPOSITION

Re-deposition (Internal transfer)

R

o

o

m

o

c

a

t

i

o

n

%

Average traveled

Totally average trip distance Re-deposition

A1 48 70% 34 m2 51 30% 15345 32 15% 4,96 22 15% 3,27 19 08 27 15% 4,19 38 15% 5,710 48 15% 7,311 59 14% 8,212 65 013 79 7% 5,514 89 4% 3,6

48,9

42,4

A

l

l

o

traveled distance

Re-Dep. 182,7Phase A transfer to end stage of Re-deposition

Phase B transfer to rooms

15-18

3.13. OPERATING TIME FOR REACH TRUCKS DURING THE PROCESS OF RE-DEPOSITION

Re-deposition time for Reach Truck is: (Retrieval from High dense & Arrangment Short-term) Average time per plt (Reach Truck) 3 min or 162 secso:Total time per plt (Reach Truck)

0,5 1,3 2,0 2,7 1,4 2,0 2,6 3,2 3,7 4,2 4,7 5,1 5,5 5,9 6,2 6,5 6,8 7,0 7,2 7,4 7,5 7,7 7,7 7,8 7,9 7,9 7,9 7,9 7,8 7,7 7,7 7,5 7,4 7,3 7,1 6,9 6,7 6,5 6,2 6,0 5,7 5,4 5,1 4,8 4,5 4,2 3,8 3,5

3.14. OPERATING TIME FOR EL. PALLETE TRUCKS DURING THE PROCESS OF RE-DEPOSITION

Sept Oct Nov DecReach Tr. Hours


- The vehicles are moving with a average speed ( U ) km/hr of U = 6 km/hr = 100 m/min

- The vehicles per trip forced into () stops = 4 stops, time loss / stop t1 t1 = 5 sec / stop = 0,1 min at cycle


- The utilization rate of the work is defined at

- Re-deposition time for Elec.Plt Trucks is: (Retrieval from High dense & Arrangment Short-term)so:

3 min or 164 sec

- Total time per plt (El. Plt Tr.)

85%

0,5 1,3 2,0 2,8 1,4 2,1 2,7 3,2 3,8 4,3 4,8 5,2 5,6 5,9 6,3 6,6 6,9 7,1 7,3 7,5 7,6 7,8 7,9 7,9 8,0 8,0 8,0 8,0 7,9 7,9 7,8 7,7 7,5 7,4 7,2 7,0 6,8 6,6 6,3 6,1 5,8 5,5 5,2 4,9 4,6 4,2 3,9 3,5El. Plt Tr. HoursJuly Aug Sept Oct Nov DecJan Feb March April May June



3.15. OPERATING TIME DURING THE SUPPLYING OF THE RIPENING ROOMS AND THE TRANSFER TO THE PICKING ZONE

Transfer to the Ripening Rooms (Internal transfer)

A

R

o

o

m

A

l

l

o

c

a

t

i

o

n

%

Average traveled

distance Wi

t

h

o

u

t

L

o

a

d

i

n

g

-

U

n

l

o

a

d

i

n

g

A

l

l

o

c

a

t

i

o

n

%

Average traveled

distance

Totally average trip distance Supplying Ripening Rooms

1 1 45 50% 23 m2 2 73 50% 3734567 m8910 67 25% 1711 57 25% 1412 013 28 25% 6,914 38 25% 9,4

15-18

47,2

94,359,0

Totally average trip distance Picking

118,0

Phase A transfer to Ripening Rooms

Phase B transfer to Picking Buffer

3.16. OPERATING TIME OF REACH TRUCKS DURING THE SUPPLYING OF THE RIPENING ROOMS

The as previously

and refer to of the plts (Placement & Retrieval)

so:

Average time per plt (Reach Truck) 2 min or 113 sec average

0,4 0,6 0,7 0,9 1,0 1,2 1,3 1,4 1,5 1,6 1,7 1,8 1,9 2,0 2,1 2,1 2,2 2,3 2,3 2,4 2,4 2,5 2,5 2,5 2,5 2,6 2,6 2,6 2,6 2,6 2,5 2,5 2,5 2,5 2,4 2,4 2,3 2,3 2,2 2,1 2,1 2,0 1,9 1,8 1,7 1,6 1,5 1,4

70%

50%

Sept Oct Nov DecReach Tr. Hours


3.17. OPERATING TIME OF ELEC. PLT TRUCKS DURING THE SUPPLYING OF THE RIPENING ROOMS

- The vehicles are moving with a average speed ( U ) km/hr of U = 6 km/hr = 100 m/min

The vehicles per trip forced into () stops = 3 stops, time loss / stop t1 t1 = 5 sec / stop = 0,1 min at cycle


Time of arrangement of one plt inside the room is 15 sec = 0,3 min = Retrieval time

The utilization rate of the work is defined at so:Average time per plt (Elec. Plt Truck) 3 min or 188 sec average

85%

0,7 1,0 1,2 1,5 1,7 1,9 2,1 2,3 2,5 2,7 2,9 3,0 3,2 3,3 3,4 3,6 3,7 3,8 3,9 4,0 4,0 4,1 4,1 4,2 4,2 4,2 4,3 4,3 4,3 4,2 4,2 4,2 4,1 4,1 4,0 3,9 3,9 3,8 3,7 3,5 3,4 3,3 3,1 3,0 2,8 2,7 2,5 2,3Elec. Plt Tr. HoursJuly Aug Sept Oct Nov DecJan Feb March April May June



3.18. OPERATING TIME DURING THE UNLOADING - ENTRY OF GOODS

Average size of unloading batch 22 plts

Instances for re-packing are where the employment of 3 workers is needed for paletizing & unloading for 30 min / load = 4,1 min /plt

The whole plts consists of of the total volume. The unloading, weighting and transfer to the deposition point is: 60 sec / plt = 1,0 min / plt

5%

88%

The mixed plts are recompositioned before the weighting and will be weighting per product code, with average time of unpacking and weighting 0 min the plt


so:

Average time per plt (in) (Unloading) 2 min or 96 sec average

7,7 10,5 13,2 15,8 18,2 20,6 22,8 25,0 27,0 29,0 30,8 32,5 34,1 35,7 37,1 38,4 39,6 40,7 41,7 42,5 43,3 44,0 44,6 45,0 45,4 45,6 45,8 45,8 45,8 45,6 45,3 45,0 44,5 43,9 43,2 42,4 41,5 40,5 39,4 38,2 36,8 35,4 33,9 32,2 30,5 28,6 26,7 24,6

3.19. OPERATING TIME DURING THE LOADING - EXIT OF GOODS

75%

DecUnoading Hours

Jan Feb March April May June Sept Oct NovJuly Aug

Required time for Plt loading 40 sec = 0,7 min

At a percetange of the plts are weighting (or checked during the exit), with average weighting time 40 sec = 0,7 min


so:

Average time per plt (out) (Loading) 1 min or 80 sec average

8,1 10,5 12,7 14,9 18,9 20,8 22,8 24,6 26,3 28,0 29,5 31,0 32,4 33,7 34,9 36,0 37,0 38,0 38,8 39,6 40,2 40,8 41,3 41,7 42,0 42,3 42,4 42,4 42,4 42,2 42,0 41,7 41,2 40,7 40,1 39,4 38,7 37,8 36,8 35,7 34,6 33,3 32,0 30,5 29,0 27,4 25,7 23,8

75%

50%

Loading HoursJuly Aug Sept Oct Nov DecJan Feb March April May June

4.SUMMARY DATA REVIEW4.1. REACH TRUCKS

max

1,35 16,75 2,8 3,7 4,7 5,6 6,4 7,2 8,0 8,9 9,6 10,3 10,8 11,6 12,2 12,7 13,3 13,9 14,4 14,7 14,8 15,1 15,5 16,0 16,0 16,4 16,7 16,7 16,8 16,5 16,7 16,6 16,4 16,1 15,9 15,9 15,7 15,2 15,1 14,7 14,2 13,8 13,1 12,7 12,1 11,8 11,3 10,8 10,1 9,6 hours1,34 10,18 0,6 1,6 2,6 3,5 1,8 2,6 3,4 4,1 4,8 5,5 6,0 6,6 7,1 7,6 8,0 8,4 8,7 9,0 9,3 9,5 9,7 9,9 10,0 10,1 10,2 10,2 10,2 10,2 10,1 10,0 9,9 9,7 9,6 9,4 9,2 8,9 8,6 8,4 8,0 7,7 7,4 7,0 6,6 6,2 5,8 5,4 4,9 4,5 hours1,34 9,56 3,6 3,4 3,3 3,3 7,7 7,7 7,6 7,7 7,7 7,7 7,8 7,8 7,9 8,0 8,1 8,2 8,3 8,5 8,6 8,7 8,8 9,0 9,1 9,2 9,3 9,5 9,6 9,7 9,7 9,8 9,9 9,9 9,9 9,9 9,9 9,9 9,8 9,7 9,6 9,5 9,3 9,1 8,9 8,6 8,3 8,0 7,6 7,2 hours2,70 7,89 0,5 1,3 2,0 2,7 1,4 2,0 2,6 3,2 3,7 4,2 4,7 5,1 5,5 5,9 6,2 6,5 6,8 7,0 7,2 7,4 7,5 7,7 7,7 7,8 7,9 7,9 7,9 7,9 7,8 7,7 7,7 7,5 7,4 7,3 7,1 6,9 6,7 6,5 6,2 6,0 5,7 5,4 5,1 4,8 4,5 4,2 3,8 3,5 hours1,89 2,56 0,4 0,6 0,7 0,9 1,0 1,2 1,3 1,4 1,5 1,6 1,7 1,8 1,9 2,0 2,1 2,1 2,2 2,3 2,3 2,4 2,4 2,5 2,5 2,5 2,5 2,6 2,6 2,6 2,6 2,6 2,5 2,5 2,5 2,5 2,4 2,4 2,3 2,3 2,2 2,1 2,1 2,0 1,9 1,8 1,7 1,6 1,5 1,4 hours

46,95 7,9 10,7 13,4 16,0 18,3 20,7 23,0 25,3 27,4 29,4 31,0 32,9 34,6 36,2 37,6 39,2 40,4 41,4 42,2 43,1 44,0 45,0 45,3 46,1 46,6 46,8 46,9 46,7 46,9 46,7 46,4 45,8 45,3 44,9 44,2 43,2 42,5 41,5 40,3 39,1 37,6 36,3 34,7 33,3 31,7 30,0 28,0 26,2 hours

ArrangementRetrieval

Nov DecMay

PickingRe-depositionRipening R.

June July Aug Sept OctAprilmin /

pltHours/

Day Jan Feb March

Total

TITLE:e.00401-AB20.04.01/04./WAREHOUSE OPERATION STUDY/CONTENTS:SUMMARY DATA REVIEW/LEAD DESIGNER:MANOLAS I. /DATE:12/10/2010

max

4.2.ELECTRICAL PALLETE TRUCKS

max

3,10 58,24 9,9 13,4 16,8 20,0 23,0 26,0 28,9 31,7 34,2 36,7 38,9 41,2 43,3 45,2 47,0 48,8 50,3 51,7 52,8 53,9 55,0 56,0 56,6 57,3 57,9 58,2 58,4 58,3 58,4 58,2 57,8 57,3 56,7 56,1 55,2 54,1 53,1 51,9 50,5 48,9 47,2 45,5 43,6 41,7 39,6 37,3 34,9 32,5 hours3,10 36,43 2,2 5,8 9,3 12,6 6,5 9,4 12,2 14,8 17,2 19,5 21,6 23,6 25,4 27,1 28,6 30,0 31,2 32,3 33,2 34,1 34,8 35,3 35,8 36,1 36,3 36,4 36,4 36,3 36,1 35,8 35,3 34,8 34,2 33,5 32,7 31,9 30,9 29,9 28,8 27,6 26,4 25,1 23,7 22,3 20,8 19,3 17,7 16,1 hours0,49 3,30 0,5 0,7 0,9 1,1 1,2 1,4 1,5 1,7 1,9 2,0 2,1 2,2 2,3 2,5 2,6 2,7 2,8 2,9 2,8 2,9 3,0 3,1 3,1 3,2 3,3 3,3 3,3 3,2 3,3 3,2 3,2 3,1 3,1 3,1 3,0 2,9 2,9 2,8 2,7 2,6 2,5 2,4 2,3 2,3 2,2 2,1 2,0 2,0 hours0,49 2,00 0,1 0,3 0,5 0,7 0,4 0,5 0,7 0,8 0,9 1,1 1,2 1,3 1,4 1,5 1,6 1,6 1,7 1,8 1,8 1,9 1,9 1,9 2,0 2,0 2,0 2,0 2,0 2,0 2,0 2,0 1,9 1,9 1,9 1,8 1,8 1,8 1,7 1,6 1,6 1,5 1,4 1,4 1,3 1,2 1,1 1,1 1,0 0,9 hours1,94 13,59 5,2 5,0 4,8 4,7 11,1 11,0 11,0 11,0 11,0 11,1 11,2 11,3 11,4 11,5 11,7 11,8 12,0 12,2 12,3 12,5 12,7 12,9 13,1 13,3 13,4 13,6 13,7 13,9 14,0 14,1 14,2 14,2 14,3 14,3 14,2 14,2 14,1 14,0 13,8 13,6 13,4 13,1 12,8 12,4 12,0 11,5 11,0 10,4 hours1,37 18,09 6,3 6,8 7,2 7,7 14,0 14,4 14,7 15,1 15,4 15,7 16,0 16,3 16,5 16,8 17,0 17,2 17,3 17,5 17,6 17,8 17,9 17,9 18,0 18,1 18,1 18,1 18,1 18,1 18,0 17,9 17,9 17,7 17,6 17,5 17,3 17,1 16,9 16,7 16,5 16,2 16,0 15,7 15,4 15,0 14,7 14,3 13,9 13,5 hours1,37 4,38 1,3 1,8 2,2 2,6 3,0 3,3 3,6 3,9 4,1 4,3 4,5 4,6 4,7 4,8 4,9 4,9 4,9 4,9 4,9 4,9 4,8 4,7 4,7 4,6 4,5 4,4 4,3 4,1 4,0 3,9 3,8 3,7 3,5 3,4 3,3 3,2 3,1 3,0 3,0 2,9 2,9 2,8 2,8 2,8 2,9 2,9 3,0 3,1 hours2,05 10,46 1,0 1,3 1,6 2,0 2,3 2,7 3,1 3,6 4,0 4,4 4,8 5,3 5,7 6,2 6,6 7,0 7,4 7,9 8,3 8,6 9,0 9,3 9,7 10,0 10,2 10,5 10,7 10,9 11,0 11,1 11,2 11,2 11,2 11,1 11,0 10,8 10,6 10,3 10,0 9,6 9,1 8,6 8,0 7,3 6,6 5,8 4,9 4,0 hours

10,19 32,67 9,4 13,1 16,4 19,5 22,3 24,8 27,0 28,9 30,6 32,1 33,4 34,4 35,2 35,9 36,3 36,6 36,8 36,7 36,6 36,3 35,9 35,4 34,9 34,2 33,5 32,7 31,8 31,0 30,1 29,2 28,2 27,3 26,4 25,6 24,8 24,0 23,3 22,7 22,2 21,7 21,4 21,2 21,1 21,2 21,4 21,8 22,4 23,1 hours9,88 130,98 45,9 49,2 52,4 55,5 101,2 104,0 106,6 109,1 111,5 113,7 115,8 117,8 119,6 121,3 122,9 124,3 125,6 126,7 127,7 128,6 129,3 129,9 130,4 130,7 130,9 131,0 130,9 130,7 130,3 129,9 129,2 128,5 127,6 126,6 125,4 124,1 122,6 121,1 119,4 117,5 115,5 113,4 111,2 108,8 106,3 103,6 100,8 97,9 hours2,74 8,00 0,5 1,3 2,0 2,8 1,4 2,1 2,7 3,2 3,8 4,3 4,8 5,2 5,6 5,9 6,3 6,6 6,9 7,1 7,3 7,5 7,6 7,8 7,9 7,9 8,0 8,0 8,0 8,0 7,9 7,9 7,8 7,7 7,5 7,4 7,2 7,0 6,8 6,6 6,3 6,1 5,8 5,5 5,2 4,9 4,6 4,2 3,9 3,5 hours3,13 4,24 0,7 1,0 1,2 1,5 1,7 1,9 2,1 2,3 2,5 2,7 2,9 3,0 3,2 3,3 3,4 3,6 3,7 3,8 3,9 4,0 4,0 4,1 4,1 4,2 4,2 4,2 4,3 4,3 4,3 4,2 4,2 4,2 4,1 4,1 4,0 3,9 3,9 3,8 3,7 3,5 3,4 3,3 3,1 3,0 2,8 2,7 2,5 2,3 hours

Nov

OUTArrangement

Decmin /

pltHours/

Day Jan Feb March April May June July Aug Sept Oct

Picking (PZ)Re-depositionRipening R.

Cross DockingTransshipment

Cross Docking (PZ

RetrievalPicking (A)Picking (B)

IN

322,40 83,0 99,6 115,5 130,5 188,0 201,5 214,1 226,1 237,2 247,6 257,1 266,1 274,4 281,9 288,8 295,1 300,6 305,3 309,3 312,9 315,9 318,6 320,1 321,6 322,4 322,4 321,9 320,6 319,3 317,3 314,7 311,5 308,1 304,4 300,0 295,1 290,1 284,4 278,4 272,0 265,0 258,1 250,5 243,0 235,0 226,7 218,0 209,2 hoursmax

4.3. LOADING - UNLOADING

max

1,61 45,84 7,7 10,5 13,2 15,8 18,2 20,6 22,8 25,0 27,0 29,0 30,8 32,5 34,1 35,7 37,1 38,4 39,6 40,7 41,7 42,5 43,3 44,0 44,6 45,0 45,4 45,6 45,8 45,8 45,8 45,6 45,3 45,0 44,5 43,9 43,2 42,4 41,5 40,5 39,4 38,2 36,8 35,4 33,9 32,2 30,5 28,6 26,7 24,6 hours1,33 42,42 8,1 10,5 12,7 14,9 18,9 20,8 22,8 24,6 26,3 28,0 29,5 31,0 32,4 33,7 34,9 36,0 37,0 38,0 38,8 39,6 40,2 40,8 41,3 41,7 42,0 42,3 42,4 42,4 42,4 42,2 42,0 41,7 41,2 40,7 40,1 39,4 38,7 37,8 36,8 35,7 34,6 33,3 32,0 30,5 29,0 27,4 25,7 23,8 hours

88,26 15,9 21,0 25,9 30,7 37,1 41,4 45,6 49,6 53,3 56,9 60,3 63,5 66,5 69,3 71,9 74,4 76,6 78,6 80,5 82,1 83,6 84,8 85,9 86,8 87,4 87,9 88,2 88,3 88,1 87,8 87,3 86,6 85,7 84,6 83,3 81,8 80,1 78,3 76,2 73,9 71,4 68,7 65,9 62,8 59,5 56,0 52,3 48,5 hoursmax

Total

July Aug Sept Octmin /

pltHours/

Day Jan Feb March April May JuneLoading

Unloading

Total

Nov Dec

5.WEEKLY DISTRIBUTION OF WORK

TITLE:e.00401-AB20.04.01/05./WAREHOUSE OPERATION STUDY/CONTENTS:WEEKLY DISTRIBUTION OF WORK/LEADDESIGNER:MANOLAS I. /DATE:12/10/2010

MondayTuesdayWednesdayThursday

Warehouse A

MondayTuesday

IN OUT Average14,8%3.110

2.3372.1603 073

11,3%12,7%13 8%

3.1532.4253.1922 760

2.647 1.8034.187 1.5873.394 1.576Wednesday

Thursday

Warehouse BIN OUT Average

17,5%22,7%19,6%14 7%2 402 1 328

-1,0%-4,3%-2,6%-0,3%0,6%

3,9%3,7%

ThursdayFridaySaturdaySunday

Monday

2.7113.5462.560

SaturdaySunday

Sum

12,1%

20.348

FridaySaturdaySunday

Sum

3.0734.721

TuesdayWednesdayThursday

21.875

13,8%17,6%17,7%3.932

2.543

2.760 ThursdayFriday

2,3%

Monday 8.288 14,8%

12 568

15.333 10.076

14,7%15,9%7,3%

2.402 1.3282.337 1.711355 1.504

15,8%6.524 4.012 Tuesday

WednesdayThursdayFridaySaturdaySunday

TOTAL STOCK .O.15.059

7.058 4.423 17,0%4.287 5.050 13,8%

15,6%5.553 4.768 15,3%5.475 4.088 14,1%

Warehouse A & BIN OUT Average

5.757 4.95618.505 8.674 11,3%10.220 8.641 12,7%

2.555 3.128 8,4%7.493 8.519 17,7%4.134 5.279 12,1%

10.452 8.214 13,8%15.721 8.477 17,6%

so:

1 ( 1 ) Warehouse A & BWork distribution ( 2 ) Total Warehouses

max

Sum

15,8%15,6%15,3%14,1%17,0%

81.584 56.092

( 1 ) Warehouse A & B

MondayTuesday

37.208 30.425 Sum

Non Working days

17,0%

13,8%8,4%

WednesdayThursdayFridaySaturdaySunday

15,8% 15,6% 15,3% 14,1%17,0%

13,8%8,4%

0%

25%

Work Distribution

6. OPERATING DATA FOR ELECTRICAL PALLETE TRUCKS6.1.WEEKLY WORK DISTRIBUTION OF ELECTRICAL PALLETE TRUCKS

ELECTRICAL PALLETE TRUCKS Work / Period

TITLE:e.00401-AB20.04.01/06./WAREHOUSE OPERATION STUDY/CONTENTS:OPERATING DATA FOR ELECTRICAL PALLETE TRUCKS/LEAD DESIGNER:MANOLAS I. /DATE:12/10/2010

8-9 9-10 10-11 11-12 12-1 1-2 2-3 3-4 8-9 9-10 10-11 11-12 12-1 1-2 2-3 3-4 hours1 2 2 2 1 2 3 2 21% 1,4% 2,7% 2,7% 2,7% 1,4% 2,7% 4,1% 2,7% 58,21 2 2 3 3 3 3 1 1% 0,1% 0,1% 0,1% 0,2% 0,2% 0,2% 0,2% 0,1% 3,32 2 2 5% 1,6% 1,6% 1,6% 0,0% 0,0% 0,0% 0,0% 0,0% 13,6

2 2 2 6% 0,0% 0,0% 0,0% 0,0% 0,0% 2,1% 2,1% 2,1% 18,11 1 1 1 1 1 2% 0,0% 0,3% 0,3% 0,3% 0,3% 0,3% 0,3% 0,0% 4,42 2 2 2 2 4% 0,0% 0,7% 0,7% 0,0% 0,0% 0,7% 0,7% 0,7% 10,5

1 2 2 3 3 12% 1,0% 2,1% 2,1% 3,1% 3,1% 0,0% 0,0% 0,0% 32,71 1 2 2 2 1 46% 5,1% 5,1% 10,3% 10,3% 10,3% 5,1% 0,0% 0,0% 131,01 1 3% 1,4% 0,0% 0,0% 0,0% 0,0% 0,0% 0,0% 1,4% 8,0

ELECTRICAL PALLETE TRUCKS Work / Period

Picking (PZ)Re-deposition

Incoming goods (IN)ArrangementPicking (A)Picking (B)Cross DockingTransshipmentCross Docking (PZ)

1 1% 1,5% 0,0% 0,0% 0,0% 0,0% 0,0% 0,0% 0,0% 4,234,4 36,0 50,5 47,1 43,2 31,7 21,1 20,1 284

Average work distribution 100% 12% 13% 18% 17% 15% 11% 7% 7%8-9 9-10 10-11 11-12 12-1 1-2 2-3 3-4 hours

Monday 5,4 5,7 8,0 7,5 6,8 5,0 3,3 3,2 45,0Tursday 5,4 5,6 7,9 7,3 6,7 4,9 3,3 3,1 44,2

Wednesday 5,2 5,5 7,7 7,2 6,6 4,8 3,2 3,1 43,3Thursday 4,9 5,1 7,1 6,7 6,1 4,5 3,0 2,8 40,2

Friday 5,8 6,1 8,6 8,0 7,3 5,4 3,6 3,4 48,2Saturday 4,7 5,0 7,0 6,5 6,0 4,4 2,9 2,8 39,2

Sunday 2,9 3,0 4,2 4,0 3,6 2,7 1,8 1,7 23,9

Work / Day

pRipening Rooms

18% 17% 15%

25%

Work Distribution

8-9 9-10 10-11 11-12 12-1 1-2 2-3 3-4MondayTursday

WednesdayThursday

Friday 8,0Saturday

Sunday

Requiered number of vehicles 12%13%

15%11%

7% 7%

0%8-9 9-10 10-11 11-12 12-1 1-2 2-3 3-4

6. OPERATING DATA FOR ELECTRICAL PALLETE TRUCKS


Suggested number of neseccarry vehicles 8Required number of vehicles 6

Utilization rate of vehiclesFor the critical hour hoursFor the critical day hours

For the critical week hoursAnnually hours

Average operating time / vehicle hours

6.2.OPERATIONAL COSTS OF ELECTRICAL PALLETE TRUCKS

100%85%72%

28412.699

48143% 9

2.116

The electrical power cost (Industrial cost terms) is: / kWh

The battery capacity for the electrical pallete trucks with hand wheel is : 24 V x 360 AH = 8,6 kWh, or: 0,86

The autonomy of vehicles with real working conditions are: 8,0 working hours, or Energy Cost: 0,11 / working hour

The annual Maintenance cost of the vehicle (Service Contract) is:

The value of the battery is: and withstands for about loading cycles, equivalent to: 0,16

so:

0,10

1.300 1.000 / working hour

/ shift

1.000

The annual operational cost is:

For each vehicle = + + =

For the total number of the vehicles =

The operational cost for each hour is: /h

Battery228,6

Energy Cost1000

Service344 1.573

9.435

0,74

6. OPERATING DATA FOR ELECTRICAL PALLETE TRUCKS


The operational cost for each Pallete is: and for each Process:

Incoming goods (IN) 0,038

0,025 0,126 0,122

Re-deposition

Outcoming goods (OUT)

RetrievalArrangement

Picking (A)Picking (B)Cross DockingTransshipmentCross Docking (PZ)

0,038 0,006 0,006 0,024

Picking (PZ)

1.599 926 88 51

428 563 133 265 989

0,017

0 034 4.074

204

0,017

Re depositionRipening Rooms 0,039

0,034 204 116

7. OPERATING DATA FOR REACH TRUCKS7.1.WEEKLY WORK DISTRIBUTION OF ELECTRICAL PALLETE TRUCKS

TITLE:e.00401-AB20.04.01/07./WAREHOUSE OPERATION STUDY/CONTENTS:OPERATING DATA FOR REACH TRUCKS/LEAD DESIGNER:MANOLAS I. /DATE:12/10/2010

Work / PeriodReach Truck

8-9 9-10 10-11 11-12 12-1 1-2 2-3 3-4 8-9 9-10 10-11 11-12 12-1 1-2 2-3 3-4 hours1 1 2 2 2 2 2 46% 0,0% 3,8% 3,8% 7,6% 7,6% 7,6% 7,6% 7,6% 16,8

2 2 2 26% 8,7% 8,7% 8,7% 0,0% 0,0% 0,0% 0,0% 0,0% 9,61 1 21% 10,7% 0,0% 0,0% 0,0% 0,0% 0,0% 0,0% 10,7% 7,91 7% 7,0% 0,0% 0,0% 0,0% 0,0% 0,0% 0,0% 0,0% 2,6

9,7 4,6 4,6 2,8 2,8 2,8 2,8 6,7 37Average work distribution 100% 26% 12% 12% 8% 8% 8% 8% 18%

8-9 9-10 10-11 11-12 12-1 1-2 2-3 3-4 hoursMonday 1,5 0,7 0,7 0,4 0,4 0,4 0,4 1,1 5,8Tursday 1 5 0 7 0 7 0 4 0 4 0 4 0 4 1 0 5 7

Work / Period

ArrangementPickingRe-deposition

Reach Truck

Work / Day

Ripening Rooms

Work distributionTursday 1,5 0,7 0,7 0,4 0,4 0,4 0,4 1,0 5,7Wednesday 1,5 0,7 0,7 0,4 0,4 0,4 0,4 1,0 5,6

Thursday 1,4 0,6 0,6 0,4 0,4 0,4 0,4 1,0 5,2Friday 1,6 0,8 0,8 0,5 0,5 0,5 0,5 1,1 6,2

Saturday 1,3 0,6 0,6 0,4 0,4 0,4 0,4 0,9 5,1Sunday 0,8 0,4 0,4 0,2 0,2 0,2 0,2 0,6 3,1

8-9 9-10 10-11 11-12 12-1 1-2 2-3 3-4MondayTursday

Wednesday

Requiered number of vehicles

26%

12% 12%

8% 8% 8% 8%

18%

0%

25%

8-9 9-10 10-11 11-12 12-1 1-2 2-3 3-4Wednesday

ThursdayFriday 2,0

SaturdaySunday


7. OPERATING DATA FOR REACH TRUCKS

TITLE:e.00401-AB20.04.01/07./WAREHOUSE OPERATION STUDY/CONTENTS:OPERATING DATA FOR REACH TRUCKS/LEAD DESIGNER:MANOLAS I. /DATE:12/10/2010

Utilization rate of vehiclesFor the critical hour hours82% 2For the critical day hours

For the critical week hoursAnnually hours

Average operating time / vehicle hours

7.2.OPERATIONAL COSTS OF REACH TRUCKS


The battery capacity for the electrical pallete trucks with hand wheel is : 48 V x 480 AH = 23 0 2 30 / shiftkWh or:

39% 633% 3729% 1.723

0,10

861

82%

The battery capacity for the electrical pallete trucks with hand wheel is : 48 V x 480 AH 23,0 2,30

The autonomy of vehicles with real working conditions are: 8,0 working hours, or Energy Cost: 0,29


The value of the battery is: and withstands for about loading cycles, equivalent to: 0,30so:The annual operational cost is:


/ working hour

/ shiftkWh, or:

/ working h

2.006

1.500

2.400 1.000

Service Battery Energy Cost1500 258 248,1


The operational cost for each hour is: /h


4.013

2,33

629

,

Arrangement 0,053 1.419 812 933

RetrievalPickingRe-deposition

0,052 0,052 0,105

220 Ripening Rooms 0,073

8. OPERATING DATA FOR ELECTRIC PEDESTRIAN TRUCKS8.1.WEEKLY WORK DISTRIBUTION OF ELECTRIC PEDESTRIAN TRUCKS

TITLE:e.00401-AB20.04.01/08./WAREHOUSE OPERATION STUDY/CONTENTS:OPERATING DATA FOR ELECTRIC PEDESTRIAN TRUCKS/LEAD DESIGNER:MANOLAS I.

ELECTRIC PEDESTRIAN TRUCKS Work / Period8-9 9-10 10-1111-12 12-1 1-2 2-3 3-4 8-9 9-10 10-11 11-12 12-1 1-2 2-3 3-4 hours

4 3 3 2 2 1 1 52% 13,0% 9,7% 9,7% 6,5% 6,5% 3,2% 3,2% 0,0% 45,81 2 3 3 3 4 48% 0,0% 0,0% 3,0% 6,0% 9,0% 9,0% 9,0% 12,0% 42,4


8-9 9-10 10-11 11-12 12-1 1-2 2-3 3-4 hoursMonday 1,8 1,4 1,8 1,7 2,2 1,7 1,7 1,7 14,0Tursday 1,8 1,3 1,8 1,7 2,1 1,7 1,7 1,7 13,7


Friday 1 9 1 5 1 9 1 9 2 3 1 8 1 8 1 8 15 0

Work / Day

Loading Unloading

25%

Work distribution

Friday 1,9 1,5 1,9 1,9 2,3 1,8 1,8 1,8 15,0Saturday 1,6 1,2 1,6 1,5 1,9 1,5 1,5 1,5 12,2

Sunday 1,0 0,7 0,9 0,9 1,1 0,9 0,9 0,9 7,4

8-9 9-10 10-11 11-12 12-1 1-2 2-3 3-4MondayTursday

WednesdayThursday

Friday 3,0S t d


13%10%

13% 13%16%

12% 12% 12%

0%8-9 9-10 10-11 11-12 12-1 1-2 2-3 3-4

SaturdaySunday


Utilization rate of vehiclesFor the critical hour hoursFor the critical day hours

For the critical week hoursAnnually hours56% 3.273,1

116% 2,394% 15,079% 88,3

Average operating time / vehicle hours1.637

8. OPERATING DATA FOR ELECTRIC PEDESTRIAN TRUCKS

TITLE:e.00401-AB20.04.01/08./WAREHOUSE OPERATION STUDY/CONTENTS:OPERATING DATA FOR ELECTRIC PEDESTRIAN TRUCKS/LEAD DESIGNER:MANOLAS I.

8.2.OPERATIONAL COSTS OF ELECTRIC PEDESTRIAN TRUCKS


The battery capacity for the electrical pallete trucks with hand wheel is : 24 V x 240 AH = 5,8 kWh, or: 0,58

The autonomy of vehicles with real working conditions are: 8,0 working hours, or Energy Cost: 0,07 / working hour


The value of the battery is: and withstands for about loading cycles, equivalent to: 0,14

so:

/ working hour

/ shift

0,10

330

1.100 1.000

The annual operational cost is:



The operational cost for each hour is: /h0,41

Service Battery Energy Cost330 225 117,8 673

1.346


0,009 652 Loading 0,011 693 Unloading

9. OPERATING DATA FOR WAREHOUSE STAFF9.1.WEEKLY WORK DISTRIBUTION OF WAREHOUSE STAFF

TITLE:e.00401-AB20.04.01/09./WAREHOUSE OPERATION STUDY/CONTENTS:OPERATING DATA FOR WAREHOUSE STAFF/LEAD DESIGNER:MANOLAS I. /DATE:12/10/2010

WAREHOUSE STAFF Work / Period8-9 9-10 10-11 11-12 12-1 1-2 2-3 3-4 8-9 9-10 10-11 11-12 12-1 1-2 2-3 3-4 hours0,1 0,1 0,2 0,2 0,2 0,1 0,1 0,1 69% 8,4% 8,8% 12,4% 11,5% 10,6% 7,8% 5,1% 4,9% 284,00,3 0,1 0,1 0,1 0,1 0,1 0,1 0,2 9% 2,4% 1,1% 1,1% 0,7% 0,7% 0,7% 0,7% 1,6% 36,80,1 0,1 0,1 0,1 0,2 0,1 0,1 0,1 22% 2,8% 2,1% 2,7% 2,7% 3,3% 2,6% 2,6% 2,6% 88,3


8-9 9-10 10-11 11-12 12-1 1-2 2-3 3-4 hoursMonday 8,8 7,8 10,5 9,6 9,4 7,2 5,5 5,9 64,8Tursday 8,6 7,7 10,3 9,5 9,3 7,1 5,4 5,8 63,7


Electric Pedestrian Trucks

Work / Day

Pallete TrucksReach Trucks

25%

Work Distribution

y , , , , , , , , ,Friday 9,4 8,3 11,3 10,3 10,1 7,7 5,9 6,4 69,4

Saturday 7,7 6,8 9,2 8,4 8,2 6,3 4,8 5,2 56,5Sunday 4,7 4,1 5,6 5,1 5,0 3,8 2,9 3,1 34,4

8-9 9-10 10-11 11-12 12-1 1-2 2-3 3-4MondayTursday

WednesdayThursday

Friday 11 0


14% 12%16% 15% 15%

11%8% 9%

0%

25%

8-9 9-10 10-11 11-12 12-1 1-2 2-3 3-4

Friday 11,0Saturday

Sunday

Suggested number of staff with simultaneous work 11Required number of staff with simultaneous work 10

Permanent staff 7Seasonal staff 3

Utilization rate of staffFor the critical hour hoursF th iti l d h

113% 11,387% 69 4For the critical day hours

For the critical week hoursPayed hours h Annually Productive hours17.694,622.420

73%87% 69,4

409,079%

9. OPERATING DATA FOR WAREHOUSE STAFF

TITLE:e.00401-AB20.04.01/09./WAREHOUSE OPERATION STUDY/CONTENTS:OPERATING DATA FOR WAREHOUSE STAFF/LEAD DESIGNER:MANOLAS I. /DATE:12/10/2010

9.2. WORK COSTS OF WAREHOUSE STAFFBasic Salary of staff on average is: overheat costs (insurrance, etc.) / kWh0,101.000 53%

Totally number of monthly salary per year: 14

Working cost / hour is: / h

The off-works for each worker in the week are: 2 the total number of staff is: 9,8 Permanent staff

The increase because of non work days is: per the basic daily salary, and regards 29% of the hours,

so the cost per hour increases at 11,2 / hso :The working cost of the Warehouse staff for the whole year is:

10,1

37,5%

The working cost of the Warehouse staff for the whole year is:

For the total staff:The working cost for productive hour is:


251.747 14,2

Incoming goods (IN)Outcoming goods (OUT)ArrangementRetrievalPicking (A)Picking (B)

0,461 0 324

0,736 0,736 0,116 0,116

30.617 17.739 1.681

974 8.193

10 775 Cross DockingPicking (B) 0,324

0,324 TransshipmentCross Docking (PZ)Picking (PZ)Re-depositionRipening Rooms

0,321 0,319 0,319

RetrievalPickingRe-depositionRi i R

0,640

Arrangement

3.897 2.230 8.665

0,486 2,415 2,343

5.700 3.841

10.775 2.538 5.081

18.937

0,649 0,743

ELECTRICAL PALLETE TRUCKS

REACH TRUCKS

78.008

4.960

Unloading 0,316

Ripening RoomsLoading 0,381

0,448

22.575

1.343 23.992 ELECTRIC PEDESTRIAN TRUCKS

10.COSTS SUMMARIES10.1. SUMMARY OF WORK DISTRIBUTION DATA

aff C

ost

hicl

es

Tota

l

TITLE:e.00401-AB20.04.01/10./WAREHOUSE OPERATION STUDY/CONTENTS:COSTS SUMMARIES/LEAD DESIGNER:MANOLAS I./DATE:12/10/2010

Staff Cost Vehicles Total

Cost / Plt Cost / Operation

Staf

Veh To

0,3 0,05 0,40,3 0,05 0,40,3 0,05 0,40,6 0,10 0,70,4 0,07 0,50,7 0,04 0,80,7 0,04 0,80,1 0,01 0,10,1 0,01 0,10,5 0,02 0,50,3 0,02 0,30,3 0,02 0,30,5 0,03 0,52,4 0,13 2,5

10.084 1.419812

8.6654.960

933629220

1.5999268851

428

5.773 6.633 4.470 1.563

32.216 18.665 1.769

Picking (A) 8.621

5.7003.8411.343

30.61717.7391.681

1.025

=>

ArrangementRetrieval

PickingRe-deposition

Ripening RoomsIncoming - Arrangement

OUT (Transfer to Order Prepar.)Arrangement

Retrieval 9748.193

10.7752.5385.081

Picking (B)Cross Docking

11.338 2.670 5.346

19.926 Cross Docking (PZ)Transshipment

56313326598918.9372,4 0,13 2,5

2,3 0,12 2,50,6 0,03 0,70,7 0,04 0,80,3 0,01 0,30,3 0,01 0,3

10.2. COSTS PER PROCESS

/ p

lt in

/ p

lt ou

t

1 06Incoming Arrangement

Unit Cost / Services Total Cost /

Services

14.794

652

2.347 24.686 23.227

266.541

Unloading

44 068

78.0083.8972.230

23.99222.575

251.747

Picking (PZ)

Ripening RoomsLoading

116693

19.926 82.082

Cross Docking (PZ)

Re-deposition 4.101

9894.074

204

18.937

16 5%1,060,40 0,361,43,8 2,92,9 2,20,50,40,4 0,31,3

0,004

4,2

Incoming - ArrangementRetrieval - Outcoming

Re-depositionPicking

TransshipmentCross Docking

LoadingUnloading

Ripening Rooms

Unit Cost / Plt

Unit Cost / Kg

44.068

1,5%23.2273.910

16,5%9,6%3,2%

40,8%8,5%2,0%9,3%8,7%

25.4638.571

108.67422.5965.346

24.686

STORAGE CALCULATION MODEL

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1 TECHNICAL COMPANY Evrou 4, Galatsi / PC 111 47, ATHENS / Tel: +30 210 29 34 140 / Fax: +30 210 21 31 145 3rd Floor Al-Rufaa Tower Doha, QATAR / Tel: +974 44 12 08 89 / Fax: +974 44 36 59 58 Email: [email protected] / Web: www.ibls.gr

Table of Contents

1. INTRODUCTION 21.1 General assumptions Procedures specification 3

1.1.1 Catgories of Services 31.1.2 Stock Handling Activities 4

1.2 Task distribution Facility resources. 71.2.1 Personnel - quipment 7

1.3 Calculation parameters 81.3.1 Distances covered 81.3.2 Activity parameters 9

1.4 Results - Total Data / Resource / Activity 11


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1. INTRODUCTION The aim of the following analysis is the calculation of the operational parameters of the logistics center, in order to specify the ancillary areas of the facility (offices, battery charging areas), machinery, personnel and the total thermal load of the facility. These parameters are the result of the selection and design of the production system of the logistics center, as it was specified in the current as well as the previous design phases.

It will become at the same time feasible to evaluate the technical characteristics of the equipment as well as the work organization model.

In a nutshell, the previous phases concern:

Throughput Volume and Storage Level Analysis (to estimate the necessary storage and operation areas) [Phase 1]

Calculation of special elements and services volume (Percentage of homogenous pallets handling, Cross Docking Picking Transfer percentages, Reference Transfer, etc.) [Phase 2]

Calculation and analysis of the fluctuation of a) Stock handling volume / storage category, b) size of incoming and outgoing loads / time unit (week, day), and c) stock level composition / size category per reference. [Phase 3]

The aforementioned phases lead to the finalization of the basic ergonomics and dimensioning of storage areas, storage area arrangement, and the arrangement of the remaining areas of the facility (Loading/Unloading, picking, packaging, ripening).

They also include the analysis and finalization of the range and fluctuation of products: per compatibility category, per storage area (high / low density storage).

All resulting data is available in the following dimensions:

Operation reference period

Compatibility & Reference category

Storage area category (high / low density)

Stock handling Activity


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This data is utilized in the analysis of stock handling procedures. In order to better comprehend the resulting data, a summary description of the basic elements follows, specifically per paragraph:

1. Summary presentation of storage areas [levels, pallets,m2] [ 01]

2. Total handling quantity [Plts] per category [ 02]

3. Stock distribution [ 03]

in high density storage and average storage period per category

in low density storage and average storage period per category

4. Operation reference period [ 04]

5. Maximum daily input handling of goods at the facility (Max / Period) [ 05]

Total unloading pallets

Distribution of input pallets between High density / Low density / Transfer / Cross Docking

6. Maximum daily output handling of goods at the facility (Max / Period) [ 06]

Total unloading pallets

Distribution of output pallets between homogenous pallets (Storage / Transfer), mixed pallets from picking.

7. Daily internal handling activities [movement of goods] from High to Low density and ripening areas [ 07]

1.1 General assumptions Procedures specification

1.1.1 Catgories of Services

The facility manages stock providing 4 general categories of services:

1. Stock storage

This concerns stock intended for storage in high and low density storage areas.

2. Stock Cross Docking


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This concerns the stock intended to supply the Picking Buffer or the Picking areas, due to the necessity to complement orders to be loaded.

3. Stock Transfer

This concerns goods which need to supply the Picking Buffer or loading areas and comprise homogenous pallets (single reference no.) which will be shipped in the same form (as homogenous pallets).

4. Fruit stock movement from short term storage to ripening areas.

1.1.2 Stock Handling Activities

[In the current design phase it was deemed necessary to specify the operational parameters without the utilization of a WMS software, which is why the model illustrates procedures in accordance with that assumption].

1.1.2.1.Unloading-receipt of Stock [ 25]

[In the present model this process includes:]

1 The unloading of pallets from trucks. This procedure is carried out with the help of Walkie Pallet Trucks.

2 Stock quality control per pallet

3 Quantity receipt per pallet

4 Homogenous pallet weighing

5 Repackaging, where necesary

1.1.2.2.Internal traffic

1 During the input of goods into storage areas [ 08,09,10,11]

Phase . This concerns the transfer of homogenous pallets from the loading/unloading area to the storage queue; as such one defines intermediate areas (Stock Buffer) before stocking in storage areas. This procedure is carried out with the help of Rider Pallet Trucks. [ 08]

Phase . This concerns the movement of pallets from the storage queue into the storage areas. This procedure is carried out with the help of Rider Pallet Trucks. In case it is possible to place pallets on the 1st level of racks then this is carried out with the help of Electric Rider - Seat Pallet Trucks, otherwise they are placed at the end of the storage chamber or to the left and right of the aisle. [ 11]


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Phase C - Ordering. This concerns the ordering of pallets in 2nd and 3rd levels of racks. This procedure is carried out with the help of Reach Trucks which are brought into storage areas with the purpose of ordering pallets which have been deposited by Electric Rider- Seat Pallet Truck drivers [ 09,10]

2 During the output of goods from storage areas [ 08,09,10,11]

i. Output of homogenous pallets: The reverse process of supplying storage areas is followed with the help of respective material handling equipment (Phase C - Reach Trucks, Phase Electric Rider - Seat Pallet Trucks, Phase Rider Pallet Trucks). Pallets are deposited in the Picking Buffer.

3 Restocking from high to short term storage areas [ 19,20,21]

Pallet retrieval. 2nd and 3rd level pallets are retrieved from racks using Reach Trucks and are deposited at the end of the storage chamber or to the left and right of the aisle [ 20]

Phase A. This concerns the transportation from high density storage areas to the restocking queue (as such one defines the end of the aisle or the area at the end of the aisle between storage chambers and the order preparation area). This procedure is carried out with the help of Rider Pallet Trucks. [ 21]

Phase . This concerns the movement from the restocking queue to the chamber of low density storage destination. This procedure is carried out with the help of Rider Pallet Trucks. [ 21]

Phase C - Ordering. This concerns the ordering of pallets in storage chambers on the 2nd and 3rd level. This procedure is carried out with the help of Reach Trucks which are brought into storage areas with the purpose of ordering pallets [ 20]

4 During the supply of ripening areas [ 22,23,24]

1. Pallet retrieval. 2nd and 3rd level pallets are retrieved from racks using Reach Trucks and are deposited at the end of the storage chamber or to the left and right of the aisle [ 23]

2. Transportation to ripening areas. This concerns the movement from low density storage to ripening areas. This procedure is carried out with the help of Rider Pallet Trucks. [ 24]

3. Ordering. This concerns the ordering of pallets in ripening chambers on the 2nd and 3rd level. This procedure is carried out with the help of Reach Trucks which are brought into storage areas with the purpose of ordering pallets. [ 23]


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1.1.2.3.Picking Buffer supply

1 Transfer ratio.

i. Transfer of pallets received at the input and supply of the Picking Buffer. This procedure is carried out with the help of Rider Pallet Trucks. [ 17]

2 From storage areas

i. Pallet retrieval (Reach Truck) [ 13]

ii. (Phase ). Movement and supply to the Picking Buffer (ordering on the first level). This procedure is carried out with the help of Rider Pallet Trucks. [ 14]

iii. Ordering on the 2nd and 3rd level of the Picking Buffer (Reach Truck) [ 13]

3 From ripening areas [ 22,23,24]

[As well as the storage chambers].

1.1.2.4.Picking Zone supply

1 Cross Docking ratio

i. Movement from reception areas and depositing per order. Weighing of quantities deposited at each point. This procedure is carried out with the help of Rider Pallet Trucks. [ 16]

1.1.2.5.Picking Order assembly

[This procedure is carried out at the Picking zone which is supplied by the picking Buffer].

i. During the picking process staff assembles a mixed pallet (assembly per order) within the Picking Zone: they collect and weigh the packets per reference and palletize the order [ 18].

ii. (Phase ). Movement from the Picking zone to the loading area. This procedure is carried out with the help of Rider Pallet Trucks. [ 15]

1.1.2.6.Loading stock output [ 26]

[In the present model this process includes:]


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1 he loading of pallets onto trucks

2 he quality control of stock per pallet

1.2 Task distribution Facility resources.

1.2.1 Personnel - quipment

All material handling activities are carried out by personnel which alternate between appropriate material handling equipment.

Facility personnel carry out three different groups of tasks, with the assumption that the supervisor has the capability to redistribute resources according to the requirements of the warehouse.

1.2.1.1. Loading/unloading personnel Walkie Pallet Truck operators.

This personnel carry out the following tasks:

a. Receipt

i. Pallet unloading

ii. Quality Quantity control

iii. Weighing of homogenous pallets

b. Loading

i. Pallet loading

ii. Quality Quantity control

The personnel consists of Walkie Pallet Ruck operators who are managed by the workflow supervisor.

These pallet trucks are flexible, appropriate for maneuvering within trucks and for spanning short distances.

1.2.1.2. Internal operations personnel Rider Pallet Truck operators.

This personnel carries out the following tasks:

a. Carrying pallets in and out of storage chambers

b. Deposit retrieval of pallets on the 1st rack level.

c. Movement and depositing of homogenous pallets at the Picking Buffer (Transfer & Collection & Ripening).


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d. Movement of mixed pallets and depositing distribution at the Picking Zone (Cross Docking).

e. Redistribution (movement from high density to short term storage areas).

f. Picking

The personnel consists of Electric Rider - Seat Pallet Truck operators who are managed by the workflow supervisor.

These pallet trucks are flexible and appropriate for spanning medium and long distances.

1.2.1.3. Ordering/Retrieval personnel Reach Truck operators.

This personnel carries out the following tasks:

a. Ordering of pallets in storage and ripening chambers and the Picking Buffer.

b. Retrieval of pallets from storage and ripening chambers and the Picking Buffer.

The personnel consists of Reach Truck operators who are managed by the workflow supervisor.

These pallet trucks are flexible and appropriate for the aisles of the chambers they have been selected for, with regard to the lifting height and weight and are capable of accommodating both storage systems (Back to Back & Drive in).

1.3 Calculation parameters

1.3.1 Distances covered

For all stock handling activities calculations of distances covered are performed per utilized resource and activity.

The calculation includes all goods input and output areas (utilization of all docks), as well as all storage areas (high and low density).

The loading and unloading areas are the same with the possibility to use the same docks for input and output at different times.

The critical areas of the facility are (activity start and end) are:

The loading and unloading area

The storage chambers


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Stock Buffer

Picking Buffer

The ripening area

The results of calculations for distances covered are provided in paragraphs 8,12,19 & 22.

1.3.2 Activity parameters

Stock handling activities are particularly complex as:

They are executed using resources with varying characteristics.

They have a different degree of difficulty (depositing on the 1st and 3rd racking level)

Performed in different places (B2B room, Drive in, aisle, FE space) They require a proper function of the necessary equipment (doors, open-

close speed, vehicle servicing, reserves)

They require an optimal organization of tasks (reduce needless movements), multitasking and

The proper administration so there is a satisfactory utilization factor of the task.

The results of the analyses, which have already been performed, and also the experience of the planners, allows the determination of the basic function parameters of the facility below:

1. Reassignment of goods from high density to short term storage. [ 7]

a. Average batch of product circulation

b. Average rest Block

2. Function parameters of Walkie Pallet Stackers (pedestrian operator) / Activity . [ 25,26]

a. Average amount of batch unloading

b. Percentage of pallets towards repackaging, necessary time, labor

c. Percentage of homogenous pallets towards weighing

d. Utilization factor of labor / activity


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e. Average necessary loading time per pallet

3. Function parameters of Reach Truck / Activity . [ 9,13,20,23]

a. Average movement speed

b. Average transportation distance travelled (from chamber - to chamber to P.B)

c. Amount of necessary stops loss of time

d. Average necessary time of fridge doors opening closing

e. Utilization factor of operation / activity

f. Average time preparation for possession depositing of the pallet in storage

g. Average time for depositing retrieval of the pallet on the rack

h. Average handled batch / chamber / storage category

4. Function parameters of rider seat pallet trucks / Activity . [ 8,11,14,15,16,17,18,21,24]

a. Average movement speed

b. Average transportation distance travelled (from chamber - to chamber to P.B)

c. Amount of necessary stops loss of time

d. Average necessary time of fridge doors opening - closing

e. Utilization factor of operation / activity

f. Degree of multitasking

g. Percentage of goods for ordering - collection

h. Average time preparation for possession depositing of the pallet in storage

i. Average time for depositing retrieval of the pallet on the rack

j. Average time of cycle for Picking - Cross Docking


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1.4 Results - Total Data / Resource / Activity

The analysis of handling procedures per activity and consumed resource, leads to comprehensive and detailed results, per operation reference period. In this manner the following information is presented:

1. The occupation of every resource / activity / reference period and the maximum price (of work per reference period) [ 27]

a. Forklifts (1)

b. Rider Pallet trucks (2)

c. Walkie pallet trucks (3)

2. The weekly distribution of the load, with the projection possibility of the results concerning a. ethoni / evgolatio or b. Total stock

3. The daily distribution of work per occupied resource and activity. The specification of maximum number of material handling equipment is made at the critical hour of the critical week. By selecting the necessary amount of MHE, we establish: the utilization factor [for the critical hour, week, and for the whole year]. For:

d. The Rider Pallet trucks (necessary amount 6 mhe) [ 29]

e. The forklifts (necessary amount 2 mhe) [ 31]

f. The walkie pallet trucks (necessary amount 2 mhe) [ 33]

4. The operating cost per occupied resource / activity and handled pallet. That specification concerns:

the consumption of electrical power (based on the function standards of the MHE)

the service cost of the machinery (annual service contract)

the battery changing cost

The results are available for:

g. The Rider Pallet trucks [ 30]

h. The forklifts [ 32]

i. The Walkie Pallet Trucks [ 34]

5. The specification of the necessary number of employees per activity category and distributed during the working day of the critical week. The choice of the number of employees, allows the specification of the utilization factor for the critical hour, day, week, and for the whole year. [ 35].


2013


6. The cost of employees per activity and pallet [ 36].

7. The total cost per activity and pallet [ 37], the unit cost per procedure [ 38]

8. Finally, the calculation of the handling unit cost per pallet and the unit cost per handled kg

e.00401-AB20.04 STORAGE CALCULATION MODEL & CAPACITY UTILIZATION RATE 1100200200209

300

e.00401-AB20.04 STORAGE CALCULATION MODEL & CAPACITY UTILIZATION RATE 2

storage calculation model & capacity utilization

Documents

basic data

operating data

loading areainternintern2

loading areatitle

costs summaries manolas

m22 high dens storage

storage datastock drive

m22 low dens storage