OMSAN LOJİSTİK

- 2 - Day 2Day 1 Session 2 – Afternoon Process and Technology Alternatives Pallet Storage Case Picking - Manual - Mechanized Session 3 – Morning Process and Technology Alternatives Small Item Picking - Order Picking Methods - Forward Pick, Slotting, and Replenishment Mechanized Picking Systems - Zone Picking - Batch Picking Session 4 – Afternoon Putting it all Together Developing the integrated design - Sizing the Functions - Defining Overall Facility Flow - Orienting Shipping and Receiving - Planning Aisle Patterns Integrating Human Activity Session 1 – Morning Defining the Problem Context - Supply Chain, Distribution Network - Single Warehouse Operations Logistics Activity Profiling Pallet Storage

- 3 - Warehousing—Do You Know? Equipment Cost, Performance, and Productivity What should one expect to pay for... –A lift truck? How about the battery? –Pallet rack? How fast does a fork truck travel? An AGV? How many cycles per hour can you achieve with... –A fork truck into and out of standard rack? –A turret truck into and out of Very Narrow Aisle (VNA) rack? –An Automated Storage and Retrieval System (AS/RS)? –An Automated Guided Vehicle (AGV)? –A double-deep reach truck... To the first position? To the rear position?

- 4 - Pallet Storage Systems Definition What does pallet storage mean for your operation? In new or “greenfield” projects, pallet storage requirements often define “how big” you need to make the box In retrofit/re-engineering projects, pallet storage definition and selection determines “how much can I fit” into the current facility* In either case, your pallet storage and retrieval decisions are heavily impacted by your business model *TPG often refers to this as our “9 Pounds In a 5-Pound Bag” program

Pallet Storage Systems Module Outline Storage modes Retrieval equipment/system modes Aisle widths Facility height Storage/retrieval mode relationships Storage/retrieval mode functional and cost comparisons Mode selection and sizing factors Demonstration/exercise

Pallet Storage Systems Storage Options Floor Stack Drive-In/Drive Through Stacking Frames Single-Deep Selective Pallet Rack Double Deep Rack Push Back Rack Flow Rack Cantilever Rack Mobile Rack Automated Storage/Retrieval System (AS/RS)

Pallet Storage Systems Storage Options Floor Stack Drive-In/Drive Through Stacking Frames Single-Deep Selective Pallet Rack Double Deep Rack Push Back Rack Flow Rack Cantilever Rack Mobile Rack AS/RS

Pallet Storage Systems Storage Options Floor Stack Drive-In/Drive Through Stacking Frames Single-Deep Selective Pallet Rack Double Deep Rack Push Back Rack Flow Rack Cantilever Rack Mobile Rack AS/RS

Pallet Storage Systems Storage Options Floor Stack Drive-In/Drive Through Stacking Frames Single-Deep Selective Pallet Rack Double Deep Rack Push Back Rack Flow Rack Cantilever Rack Mobile Rack AS/RS

Pallet Storage Systems Storage Options Floor Stack Drive-In/Drive Through Stacking Frames Single-Deep Selective Pallet Rack Double Deep Rack Push Back Rack Flow Rack Cantilever Rack Mobile Rack AS/RS

Pallet Storage Systems Storage Options Floor Stack Drive-In/Drive Through Stacking Frames Single-Deep Selective Pallet Rack Double Deep Rack Push Back Rack Flow Rack Cantilever Rack Mobile Rack AS/RS

Pallet Storage Systems Storage Options Floor Stack Drive-In/Drive Through Stacking Frames Single-Deep Selective Pallet Rack Double Deep Rack Push Back Rack Flow Rack Cantilever Rack Mobile Rack AS/RS

Pallet Storage Systems Storage Options Floor Stack Drive-In/Drive Through Stacking Frames Single-Deep Selective Pallet Rack Double Deep Rack Push Back Rack Flow Rack Cantilever Rack Mobile Rack AS/RS

Pallet Storage Systems Storage Options Floor Stack Drive-In/Drive Through Stacking Frames Single-Deep Selective Pallet Rack Double Deep Rack Push Back Rack Flow Rack Cantilever Rack Mobile Rack AS/RS

Pallet Storage Systems Storage Options Floor Stack Drive-In/Drive Through Stacking Frames Single-Deep Selective Pallet Rack Double Deep Rack Push Back Rack Flow Rack Cantilever Rack Mobile Rack AS/RS

Pallet Storage Systems Retrieval Options Pallet jack Walkie Stacker Counterbalanced Straddle Straddle Reach Turret (Swing reach) Swing Mast (Drexel) Sideloader AS/RS

Pallet Storage Systems Retrieval Options Pallet jack Walkie Stacker Counterbalanced Straddle Straddle Reach Turret (Swing reach) Swing Mast (Drexel) Sideloader AS/RS

Pallet Storage Systems Retrieval Options Pallet jack Walkie Stacker Counterbalanced Straddle Straddle Reach Turret (Swing reach) Swing Mast (Drexel) Sideloader AS/RS

Pallet Storage Systems Retrieval Options Pallet jack Walkie Stacker Counterbalanced Straddle Straddle Reach Turret (Swing reach) Swing Mast (Drexel) Sideloader AS/RS

Pallet Storage Systems Retrieval Options Pallet jack Walkie Stacker Counterbalanced Straddle Straddle Reach Turret (Swing reach) Swing Mast (Drexel) Sideloader AS/RS

Pallet Storage Systems Retrieval Options Pallet jack Walkie Stacker Counterbalanced Straddle Straddle Reach Turret (Swing reach) Swing Mast (Drexel) Sideloader AS/RS

Pallet Storage Systems Retrieval Options Pallet jack Walkie Stacker Counterbalanced Straddle Straddle Reach Turret (Swing reach) Swing Mast (Drexel) Sideloader AS/RS

Pallet Storage Systems Retrieval Options Pallet jack Walkie Stacker Counterbalanced Straddle Straddle Reach Turret (Swing reach) Swing Mast (Drexel) Sideloader AS/RS

Pallet Storage Systems Retrieval Options Pallet jack Walkie Stacker Counterbalanced Straddle Straddle Reach Turret (Swing reach) Swing Mast (Drexel) Sideloader AS/RS

Pallet Storage Systems Aisle Options Conventional(12-15’ aisle) Narrow aisle(8-10’ aisle) –Conventional height –Mid-rise Very narrow aisle(4.5-6’ aisle) –Aisle captive –Aisle to aisle –Mid-rise –High-rise Automated storage/retrieval(4-5’ aisle)

Pallet Storage Systems Facility Height Options Conventional 18-25’ Mid-rise 25-40’High rise ’

Pallet Storage Systems Storage Mode/Retrieval Mode Relationships

Double Deep Single Deep AA Pallet Storage Systems Aisle Widths A

Pallet Storage Systems Retrieval Options Comparison

Pallet Storage Systems Cost and Usability Comparison

Pallet Storage Systems Key Factors In Determining Storage Mode Requirement for FIFO & lot control Typical receipt size Handling unit received versus handling unit shipped Turn rate of storage unit Overall storage requirement Overall velocity Pick from storage versus pick from forward area Stacking characteristics Controls capability –Random versus storage capability –Computer visibility of locations and inventory –Directed activities Special needs, e.g. aerosol, chemicals...

Pallet Storage Systems Ways To Size Storage Utilization study of existing operations - measure current floor space requirements and factor in future business growth Measure current cube requirements and reapply to new storage equipment Historical database analysis—by SKU, analyze historical inventories, receipt sizes and sales velocity and factor in business growth ABC product/SKU analysis—categorize each SKU into classes by sales velocity: –Establish inventory targets by class –Multiply SKU cube x inventory target and sum Service level expectations - Establish SKU or family target inventories based on economic order quantities, lead time variability, margins Inventory simulation

Off-Site Floor Storage Pallet Flow Lanes Double Deep Rack Push-Back Rack Single-Deep rack Popularity Floor Storage Drive-In Drive-Through Pallets on-Hand <1 Small Parts Storage Pallet Storage Systems Example Hybrid Storage Systems Design

Pallet Storage Systems Demonstration/Exercise 20,000 sq. ft. available for unit load storage... –100’ wide x 200’ long –40’ clear height –Just to be nice, there are no columns –The 100’ wide ends are both open, the 200’ sides have walls; material flows in one end and out the other Loads are... –Palletized, stretch wrapped, and highly stable –Uniformly 40” wide x 48” deep x 60” high, each holds 100 cases –Floor stack height is 3 loads Compare pallet capacity for two scenarios: Scenario 1: Block stack storage Counterbalance trucks ’ aisles 48” square floor positions Scenario 2: VNA single deep w/turret trucks 5 ½ ’ aisles 8’ bays 6 high

Pallet Storage Systems Demonstration/Exercise – Scenario 1 Scenario 1: Block stack storage Counterbalance trucks Two 12’ aisles 48” square positions 100’ 200’ Were it not for the inconvenience of needing aisles, this space could hold 3,750 of our pallets, or 375,000 cases, where 200’/4’ = 50 pos 100’/4’ = 25 pos 25 x 50 = 1,250 pos x 3 high = 3,750 pall X 100 cs/pall = 375K cs

Pallet Storage Systems Demonstration/Exercise – Scenario 1 Scenario 1: Block stack storage Counterbalance trucks Two 12’ aisles Lane depth, 4-5 pallets 48” square positions 100’ 200’ Per our spec, we need 2 12’ aisles, leaving 76’ of width, therefore ’/4’ = 50 pos 76’/4’ = 19 pos 19 x 50 = 950 pos x 3 high = 2,850 pall X 100 cs/pall = 285K cs

Pallet Storage Systems Demonstration/Exercise – Scenario 2 100’ 200’ Scenario 2: VNA single deep w/turret trucks 5 ½ ’ aisles 8’ bays 6 high Assuming 14’ for each aisle/rack set, you have enough room for 7 aisles, therefore ’/8’ = 25 bays x 2 pos = 50 pos x 6 high = 300 pall/row x 14 rows = 4,200 pall X 100 cs/pall = 420K cs This one gets a little trickier, because you need to figure out how many aisles and racks you can fit in the space. In this example, one complete aisle and rack is 14’ (5.5’ aisle plus 2 x 4’ racks plus 6” flue between racks). Aisle Left Rack Right Rack

Pallet Storage Systems Demonstration/Exercise – Discussion Points Which scenario was better? Why? Why did the VNA solution yield so much more capacity? Which is more flexible? Which is more costly to implement? Why would you choose one over the other? Could you imagine a hybrid situation in which both modes may be indicated?

Pallet Storage Systems Mind the Data—What Space You Need May Surprise You! In this example, the facility had a high proportion of 10-deep bulk storage lanes. As the data shows, very few SKUs are right for 10-deep storage. The facility will be more efficient with a blend that includes shallower lanes and more facings.

Pallet Storage Systems Storage Sizing Rules—Be Flexible! Use sensitivity analysis to understand and explore risks Determine if it is better to invest on the high side vs. adding incremental space later. Have plan established for dealing with too little space –Build on or add to lease –Surge warehouse –Drop ship to customers –Improve turns on high cube items –Cross dock