Storage Calculation Model & Capacity Utilization

AB20.
04 STORAGE CALCULATION MODEL & CAPACITY

UTILIZATION RATE
Fruit Cold Store
CLIENT:
LFC
PROJECT: Logistics Center in Thiva
DOCUMENTCODE: 501.AB20.04 STORAGE CALCULATION MODEL & CAPACITY UTILIZATION RATE.Rev.1
O t b 12,
October
12 2010
Signer:
I. Manolas / Technical Director
Checked:
1. Receiving Loading
Area
Internal
ternal tra
traffic
Stock
ck
(B2B)
B)
Stock
ck
Internal
ternal tra
traffic
Stock
ck
(B2B)
B)
Stock (Drive in)
Stock
ck
(B2B)
B)
Stock
ck
(B2B)
B)
Stock (Drive
(
in))
Area
Area
Area
TITLE:e.00401-AB20.04.01-CONTENS:WAREHOUSE OPERATION STUDY-PROJECT MANAGER:MANOLAS I.-12/10/2010
CLIENT:
PROJECT: CP26 - Training and Operation & Maintenance Manuals
DELIVERABLES
TITLE:
PROJECTMANAGER:
DATE:
DOCUMENT CODE
DOCUMENTCODE:
WAREHOUSE OPERATION STUDY

MANOLAS I.
12/10/2010
e 00401 AB20 04 01
e.00401-AB20.04.01
CONTENTS
LEADDESIGNER
DATE
01.
BASIC DATA OF THE WAREHOUSE
MANOLAS I.
12/10/2010
02.
PRODUCT HANDLING & CALCULATION DATA
MANOLAS I.
12/10/2010
03
03.
TIME CALCULATIONS OF GOODS TRANSFER PROCESSES
MANOLAS II.
12/10/2010
04.
SUMMARY DATA REVIEW
MANOLAS I.
12/10/2010
05.
WEEKLY DISTRIBUTION OF WORK
MANOLAS I.
12/10/2010
06.
OPERATING DATA FOR ELECTRICAL PALLETE TRUCKS
MANOLAS I.
12/10/2010
07.
OPERATING DATA FOR REACH TRUCKS
MANOLAS I.
12/10/2010
08.
OPERATING DATA FOR ELECTRIC PEDESTRIAN TRUCKS
MANOLAS I.
12/10/2010
09.
OPERATING DATA FOR WAREHOUSE STAFF
MANOLAS I.
12/10/2010
10.
COSTS SUMMARIES
MANOLAS I.
12/10/2010
TITLE:e.00401-AB20.04.01/01./WAREHOUSE
DESIGNER:MANOLAS I. /DATE:12/10/2010
OPERATION
STUDY/CONTENTS:BASIC
DATA
OF
THE
WAREHOUSE/LEAD
1.BASIC DATA OF THE WAREHOUSE

1.1.GENERAL BUILDING AND STORAGE DATA
2
2
8
2
4
18
Area
Intern
nal traffic
Stoc
ck
(B2B
B)
Intern
nal traffic
Stoc
ck
Stoc
ck
(B2B
B)
Stock (Drive in)
Stoc
ck
(B2B
B)
Stoc
ck
(B2B
B)
Stock (Drive in)
High
Hi
h dens
d
storage
t
rooms
High dens storage rooms
Low dens storage rooms
Low dens storage
g rooms
Banana ripening rooms
3
3
3
3
2
Area
Level
Le
el
Level
Level
Level
Level
540
420
198
108
20
plts
plts
plts
plts
p
plts
Rooms total
Area
1.080
1
080
840
1.584
216
80
plts
plts
plts
plts
p
plts
3.800
plts 3.658
785
629
1904
240
99
m2
m2
m2
m2
m2
m2
And 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
Kiwis 02
Apples 03
Pears 04
Potatoes 05
Onions - Garlic 06
Tomatoes 07
Cabbages - Peppers 08
Bananas 09
Fruits 10
Dry
y bulk 11
Rest prod. 12
23.500
23
500
1.000
7.500
4.500
8.000
3.500
2.000
7 000
7.000
500
1.000
500
1.000
plts
plts
plts
plts
plts
plts
plts
plts
plts
plts
plts
plts
60.000 plts
Area
OPERATION
STUDY/CONTENTS:BASIC
DATA
OF
THE
WAREHOUSE/LEAD
1.BASIC DATA OF THE WAREHOUSE

1.3. STORAGE DATA
At the High Dens Storage
Citrus
Citr s Fruits
Fr its 01
Apples 03
Pears 04
Potatoes 05
O i
Onions
- Garlic
G li 06
Citrus Fruits (out)
With an average residence

time
4.877
4 877
3.112
2.291
1.832
1 141
1.141
plts
plts
plts
plts
plts
lt
41
30
33
37
33
days
da s
days
days
days
d
days
13.254 plts
36 days
8.030 plts
41 days
21.284 plts
Note 1
Hi h dense
High
d
storage
t
is
i defined
d fi d as the
th medium
di
to
t long
l
storage
t
duration
d ti when
h th
the fi
fi-fo
f effected
ff t d partly
tl b
by llots
t - bl
block
k over 15
pallets
At the Low
dens storage
Citrus Fruits 01
Kiwis 02
Apples 03
Pears 04
Potatoes 05
Onions - Garlic 06
Tomatoes 07
Cabbages - Peppers 08
Bananas 09
Fruits 10
Dry bulk 11
Rest prod. 12
7.784
735
3.224
1.623
4.532
1.734
1.470
5.144
367
735
367
735
plts
plts
plts
plts
plts
p
plts
plts
plts
plts
plts
plts
plts
28 448 plts
28.448
lt
With an average
residence time
16
7
21
15
14
11
6
6
0
5
4
20
Indicated values of 2001

(High & Low Density)
days
days
days
days
days
y
days
days
days
days
days
days
days
17 days
d
14
9
23
19
13
8
6
6
1
9
15
32
days
days
days
days
days
y
days
days
days
days
days
days
days
14 days
d
Note 2
Low dense storage is defined as the short-term storage duration when the fi-fo process is implementing totaly
Note 3
It 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.
TITLE:e.00401-AB20.04.01/02./WAREHOUSE OPERATION STUDY/CONTENTS:PRODUCT HANDLING & CALCULATION DATA/LEAD DESIGNER:MANOLAS I. /DATE:12/10/2010
2.PRODUCT HANDLING & CALCULATION DATA

2.1. OPERATING TIME OF WAREHOUSE
The operating time of the Center is divided into 48 periods (4 / month). The number of days per period are:
Jan
8
Feb
Note 4
The center manages the stocks with 4 general categories of services.
March
7
April
7
May
911
944
June
7
July
7
Aug
8
Sept
8
Oct
8
Nov
8
979
949
918
883
Dec
7
847
807
765
721
674
624
A) For storage stocks (dense and short)

B) For Cross Docking Stocks
C) The Stocks to Transhipment
B
t k (which
( hi h will
ill b
f
d tto th
i
i rooms))
D) Banana
stock
be ttransferred
the ripening
In the initial quantities of goods extra quantities transported Banana are added
2.2. MAXIMUM DAILY INCOMING GOODS HANDLING OF THE CENTER

The max. daily handling of the Center (max/Period) Incoming goods is:
Annual Handling
(indicative values 2010)
2010
Jan
Feb
March
April
May
June
July
Aug
Sept
Oct
Nov
Dec
TRAN.
To storage
70%
41.702
66%
192 260 325 388 449 506
To High
T
Hi h dense
d
storage
t
To Low Dense storage
22%
13 2 4
13.254
21%
142
180
19
195
21
215
192
228
248
261
282
334
348
332
286
298
316
382
334
391
436
42
425
41
415
3 6
356
399
386
3 4
374
320
313
3 2
352
346
301
333
31
315
29
297
2 8
278
231
248
218
2
257
266
286
269
309
28.448
45%
0%
0%
9 111 103 119

97
47%
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
Cross Docking
17%
10.458
17%
13%
7.840
12%
Unloading (Plts in)

Unloading
U
l di Bananas
B
(Plts
(Plt in)
i )
Unloading (Plts in)
100%
60.000
100%
0%
3.000
5%
100%
63.000
105%
63
0%
0%
68
664
712
757
799
839
877
973 1000 1025 1047 1066 1083 1098 1109 1118 1125 1129 1131 1130 1126 1120 1111 1100 1086 1070 1051 1029 1005
37
47
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
116
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
0%
5%
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
876
37
41
44
105%
289 393 493 589 681 769
853
19
23
28
69
614
28
14
58
562
32
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
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:
Note 5
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
pallets. Mixed pallets typically have smaller volume resulting in the output number of the wood is greater than the input.
Picking (plts in)
Annual Handling
(indicative values 2010)
Vol. increase of Plts due Picking

Picking (plts in)
Picking (plts out)
31%
17.767
28%
23.097
23 097
Picking from High Dense storage

-
Jan
30%
0%
7%
Feb
March
April
May
June
July
Aug
Sept
Oct
Nov
Dec
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
321
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
692
694
694
692
687
681
673
663
652
638
624
607
589
569
548
526
503
478
452
425
396
367
337
306
1.244
and from Low Dense
16.523
Exit from storage rooms (Plts in)
Total Exit
40%
(Plts in)
(S. plt.) Exit from High Dense
(S plt
(S.
plt.)) Exit from High Dense
20%
20%
100%
63.000
57%
34.213
54%
3 900
3.900
33.289
119%
71.402
Loading (Plts in)

Loading only whole
Bananas (out)
Loading only mixed plts.
Loading (Plts in & out)
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
12.010
19%
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
19%
21
11 925
11.925
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
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
998
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
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
57
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
23.755
5%
-
18
24
31
36
42
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
TITLE:e.00401-AB20.04.01/02./WAREHOUSE OPERATION STUDY/CONTENTS:PRODUCT HANDLING & CALCULATION DATA/LEAD DESIGNER:MANOLAS I. /DATE:12/10/2010
2.PRODUCT HANDLING & CALCULATION DATA

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 6
Internal 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
pallets.
Average batch product handling
Average rest of Block
i=
10
plts at the high dense k
pallets
Jan
Internal trasfer
10%
6.005
10%
10
28
Feb
45
61
31
45
23
28
32
37
59
March
71
83
44
48
94
104
April
114
122
58
61
130
May
138
144
150
155
68
70
72
June
160
164
167
76
77
170
July
172
174
175
175
80
81
81
Aug
175
175
174
172
82
81
81
Sept
170
168
165
161
80
79
78
Oct
158
153
149
144
75
74
72
Nov
139
133
127
121
70
68
66
63
Dec
114
107
100
93
57
54
51
85
77
47
44
Note 7
Internal transfers also define the suppling of the Banana ripening rooms
Jan
Internal transfer ripening rooms
3.000
14
19
Feb
41
March
52
55
April
63
May
66
June
74
78
July
79
Aug
81
Sept
81
Oct
77
Nov
Dec
60
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
3. TIME CALCULATIONS OF GOODS TRANSFER PROCESSES

3.1. OPERATING TIME OF ELECTRO PALLET TRUCKS DURING IN - OUT OF GOODS
Phase A
transfer at
end line of
storage
Phase B
transfer to
rooms
Average
traveled
distance
48 47%
23
51 53%
27
32 24%
7,8
22 24%
5,2
19
4%
0,8
27 24%
6,5
38 24%
9,1
1
2
3
4
49,6
35
Alloca
ation %
A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Withoutt Loading Unloading
Ro
oom
In - Out of Goods
Alloca
ation %
The average distance per room of internal transfer vehicles is:

Totally average trip
distance In
In-Out
Out
Average
traveled
distance
5%
1,8
38 40%
15
66 40%
26
92 15%
14
High D.
Low D.
213,5
172,8
m
m
57,2
29,3
15-18
The vehicles are moving with a average speed ( U ) km/hr of
U=
km/hr
The vehicles per trip forced into () stops
stops, time loss / stop t1
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
100
m/min
10 plts at High dense k
The utilization rate of the work is defined at
85%
The complexity rate of work for In - Out is defined at
5%
t1 =
sec / stop = 0,1 min
plts at Low Dense
so:
Average trip time (Elect. Pallet trucks)
3,1 min
or
186 sec
Total operating time of Pallet trucks during In - Out of goods

Jan
Feb
March
April
May
June
July
Aug
Sept
Oct
Nov
Dec
(in)
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
32
(out)
13
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
Hours
Hours
El. Plt Truck
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
Hours

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
The forklifts per trip forced into () stops
4 stops
Time loss per stop ( t1 )
t1 =
The average opening and closing time for the doors at the cold rooms are ( T2 )
83 m/min
T2 = 0,3 min (during transfer)

80%
3.4. OPERATING TIME OF ELECTRICAL PALLET TRUCKS

Service Load Ratio between Reach Truck and Electrical Pallet Trucks
65%
of the total load
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
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 sec
Total
for
Retrieval
Truck)
T t l time
ti
f Arrangment
A
t-R
ti
l (Reach
(R
hT
k)
Jan
Feb
March
April
May
June
July
Aug
Sept
Oct
Nov
Dec
Arrangment
Retrieval
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
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
Hours
Hours
Reach T
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
Hours
Hours
Hours
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
0,5
29 sec
Total time for Arrangment - Retrieval (El. Pallete Truck)

Jan
Feb
March
April
May
June
July
August
September
October
November
December
Arrangment
Retrieval
El. Plt Truck
3 Hours
Phase A
transfer to
Picking Buffer
Phase B
transfer to
Loading
15-18
78
5%
3,9
81
2%
1,6
63 23%
14
52 23%
12
30
1%
0,3
25 23%
5,8
15 23%
3,5
1
2
3
4
50
Allocation %
A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Average
A
traveled
distance
Without Loading Unlo

oading
Picking - Cross Docking goods
Allocation %
Ro
oom
3.5. OPERATING TIME DURING THE PROCESSES OF CROSS DOCKING - PICKING - TRANSSHIPMENT
5%
Average
A
traveled
distance
Picking
2,5
20 40%
48 40%
19
78 15%
12

di t
distance
Pi
Picking
ki
distance
di
t
Mi
Mixed
dP
Pallets
ll t
41,4

distance Picking
Cross Docki
41,2
82,5
82,8
Mix Plts
82,8

distance
Transshipment
Mix Plts
110,4

3.6. OPERATING TIME OF REACH TRUCK DURING PICKING
(as previously)
so:
Average time per plt (Reach Truck)
1,3 min
Jan
Reach T
3,6
3,4
or
Feb
3,3
3,3
7,7
7,7
81 sec
March
7,6
7,7
7,7
7,7
7,8
April
7,8
7,9
8,0
May
8,1
8,2
8,3
8,5
June
8,6
8,7
8,8
9,0
July
9,1
9,2
9,3
9,5
Aug
9,6
9,7
9,7
9,8
Sept
9,9
9,9
9,9
9,9
Oct
9,9
9,9
9,8
9,7
Nov
9,6
9,5
9,3
9,1
Dec
8,9
8,6
8,3
8,0
13
12
12
12
15
15
15
14
7,2
Hours
11
10
Hours
14
14
Hours
Hours
7,6
3.7. OPERATING TIME OF ELEC. PALLETE TRUCK DURING PICKING AT CYCLE A

U=
5 km/hr
4 stops, time loss / stop t1
t1 =
at cycle
t1 =
at cycle
t1 =
at transshipment
m/min
83
T2 = 0,3
, min
The average
g opening
p
g and closing
g time for the doors at the cold rooms are (T2)
( )
1 plts
The opening of the doors will be done per

85%
so
Average time per plt (in) (El. Plt Truck)
Jan
Plt Truck (A)
1,9 min or
Feb
5
11
11
117 sec
March
11
11
11
11
11
April
11
11
12
May
12
12
12
12
June
12
13
13
13
18
18
July
13
13
13
14
18
18
18
18
Aug
14
14
14
14
18
18
18
Sept
14
14
14
14
18
18
17
Oct
14
14
14
14
17
17
17
Nov
14
14
13
13
16
16
16
16
Dec
3.8. OPERATING TIME OF ELEC. PALLETE TRUCK DURING TOTAL PICKING AT CYCLE B
(respectively)
so:
Average time per plt (out) (El. Plt Truck)
Jan
Plt Truck (B)
1,4 min or
Feb
7
14
14
82 sec
March
15
15
15
16
16
April
16
17
17
May
17
17
17
18
June
18
18
July
Sept
Aug
18
18
Oct
17
Nov
Dec
3.9. OPERATING TIME OF ELEC. PALLETE TRUCK DURING CROSS DOCKING AT CYCLE B
(as previously)
so:
Jan
Plt Truck (B)
1,4 min or
Feb
2
82 sec
March
4
April
5
May
5
June
5
July
4
Aug
4
Sept
4
Oct
3
Nov
3
Dec
3

3.10. OPERATING TIME OF ELEC. PALLETE TRUCK DURING TRANSSHIPMENT AT CYCLE B
(as previously)
so:
Jan
Plt Truck (B)
2,0 min or
Feb
123 sec
March
3
April
5
May
7
June
8
July
Sept
Aug
Oct
Nov
Dec
5
Hours
22
23
Hours
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
Hours
10
10
10
10
11
11
11
11
11
11
11
11
11
11
11
10
10
10
21
21
21
22
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
U=
4 km / hr
67 m / min
85%
During Cross Docking

The Mix plt follow inside the Picking zone a trip of
deposition points with time loss
60 sec / point =
1,0 min
Also is forced to
safety stops with time loss
0,1 min
sec / stop =
20 m / weighting with time loss
60 sec =
1,0 min (for stops, deposition - retrieval at the weighter and note indications)
The Mix plt follow inside the Picking zone a trip of
picking points with time loss
40 sec / point =
0,7 min
Also is forced to
safety stops with time loss
0,1 min
Weighting for
100%
of the goods is done, with a distance
During Picking
Weighting for
50%
of the goods is done, with a distance
20 m / weighting with time loss
Paletizing for
95%
of the goods is done

done, with a average time
30 sec =
so:
Average time per plt (in) (Cross Docking) (for breaking)
Jan
El. Pal.(p z)
13
Feb
16
20
22
25
10 min or
March
27
29
31
32
33
Average time per plt (out) (Picking) (for composition)

Jan
El. Pal.(p z)
46
49
Feb
52
35
36
9,9 min or
March
50 sec =
0,8 min (for stops, deposition - retrieval at the weighter and note indications)
0 5 min
0,5
611 sec
average (for the sum of the plts)
April
34
sec / stop =
36
May
37
593 sec
April
37
37
37
June
36
36
35
July
35
34
33
33
32
Aug
31
30
29
28
Sept
27
26
26
25
Oct
24
23
23
Nov
22
22
21
21
Dec
average (for the sum of the plts)

May
June
55 101 104 107 109 112 114 116 118 120 121 123 124 126 127 128 129 129 130
July
Aug
Sept
Oct
Nov
Dec
Room
Re-deposition (Internal transfer)
A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Phase A
transfer to
end stage of
Re-deposition
Phase B
transfer to
rooms
Allo
ocation %
3.12. OPERATING TIME DURING THE PROCESS OF RE-DEPOSITION

distance Redeposition
Average
traveled
distance
48 70%
34
51 30%
15
32 15%
4,9
22 15%
3,2
19
Re-Dep. 182,7
48,9
27 15%
4,1
38 15%
5,7
48 15%
7,3
59 14%
8,2
65
79
7%
5,5
89
4%
3,6
42,4
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)
so:
Total time per plt (Reach Truck)
Jan
Reach Tr.
0,5
1,3
2,0
Feb
2,7
1,4
2,0
2,6
March
3,2
3,7
4,2
4,7
April
5,1
5,5
5,9
6,2
May
6,5
6,8
7,0
7,2
June
7,4
7,5
7,7
7,7
3 min or
July
7,8
7,9
7,9
7,9
162 sec
Sept
Aug
7,9
7,8
7,7
7,7
7,5
7,4
7,3
7,1
Oct
6,9
6,7
6,5
6,2
Nov
6,0
5,7
5,4
5,1
Dec
4,8
4,5
4,2
3,8
3,5
Hours
3,5
Hours
3.14. OPERATING TIME FOR EL. PALLETE TRUCKS DURING THE PROCESS OF RE-DEPOSITION
-
U=
km/hr
t1 =
at cycle
t1 =
at cycle
Re-deposition time for Elec.Plt Trucks is: (Retrieval from High dense & Arrangment Short-term)
so:
3 min or
100
m/min
85%
164 sec
Total time per plt (El. Plt Tr.)

Jan
El. Plt Tr.
0,5
1,3
2,0
Feb
2,8
1,4
2,1
2,7
March
3,2
3,8
4,3
4,8
April
5,2
5,6
5,9
6,3
May
6,6
6,9
7,1
7,3
June
7,5
7,6
7,8
7,9
Aug
July
7,9
8,0
8,0
8,0
8,0
7,9
7,9
7,8
Sept
7,7
7,5
7,4
7,2
Oct
7,0
6,8
6,6
6,3
Nov
6,1
5,8
5,5
5,2
Dec
4,9
4,6
4,2
3,9
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Phase B
transfer to
Picking Buffer
Average
traveled
distance
45 50%
Average
traveled
distance
23
73 50%
37
1
2
Allocation %
Phase A
transfer to
Ripening
Rooms
Without Loading Unloading
Room
Transfer to the Ripening Rooms (Internal transfer)
Allocation %
3.15. OPERATING TIME DURING THE SUPPLYING OF THE RIPENING ROOMS AND THE TRANSFER TO THE PICKING ZONE
distance Supplying
Ripening Rooms
94,3
59,0
distance Picking
67 25%
17
57 25%
14
28 25%
6,9
38 25%
9,4
118,0
47,2
15-18
3.16. OPERATING TIME OF REACH TRUCKS DURING THE SUPPLYING OF THE RIPENING ROOMS
The
as previously
70%
and refer to
of the plts (Placement & Retrieval)
50%
so:
2 min or
Jan
Reach Tr.
0,4
0,6
0,7
Feb
0,9
1,0
1,2
113 sec
average
March
1,3
1,4
1,5
1,6
1,7
April
1,8
1,9
2,0
2,1
May
2,1
2,2
2,3
2,3
June
2,4
2,4
2,5
2,5
July
2,5
2,5
2,6
2,6
Sept
Aug
2,6
2,6
2,6
2,5
2,5
2,5
2,5
2,4
Oct
2,4
2,3
2,3
3,9
3,9
3,8
2,2
Nov
2,1
2,1
2,0
3,5
3,4
3,3
1,9
Dec
1,8
1,7
1,6
3,0
2,8
2,7
1,5
1,4
Hours
2,3
Hours
3.17. OPERATING TIME OF ELEC. PLT TRUCKS DURING THE SUPPLYING OF THE RIPENING ROOMS
-
U=
km/hr
t1 =
at cycle
t1 =
at cycle
15 sec =
Time of arrangement of one plt inside the room is

Jan
0,7
1,0
1,2
3 min or
Feb
1,5
1,7
100
m/min
0,3 min
= Retrieval time
85%
so:
Average time per plt (Elec. Plt Truck)
Elec. Plt Tr.
1,9
2,1
188 sec
average
March
2,3
2,5
2,7
2,9
April
3,0
3,2
3,3
3,4
May
3,6
3,7
3,8
3,9
June
4,0
4,0
4,1
4,1
July
4,2
4,2
4,2
4,3
Aug
4,3
4,3
4,2
4,2
Sept
4,2
4,1
4,1
4,0
Oct
3,7
Nov
3,1
Dec
2,5

3.18. OPERATING TIME DURING THE UNLOADING - ENTRY OF GOODS
22 plts
Average size of unloading batch
3 workers is needed for paletizing & unloading for
Instances for re-packing are
5%
where the employment of
The whole plts consists of
88%
of the total volume. The unloading, weighting and transfer to the deposition point is:
The mixed plts are recompositioned before the weighting and will be weighting per product code, with average time of unpacking and weighting
30 min / load =
4,1 min /plt
60 sec / plt =
1,0 min / plt
min the plt
75%
so:
Average time per plt (in) (Unloading)
Jan
Unoading
2 min or
Feb
96 sec
average
March
April
May
June
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
July
Aug
Sept
Oct
Nov
Dec
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
Hours
3.19. OPERATING TIME DURING THE LOADING - EXIT OF GOODS

40 sec =
Required time for Plt loading

50%
At a percetange of
0,7
min
the plts are weighting (or checked during the exit), with average weighting time
40
sec =
0,7 min
75%
so:
Average time per plt (out) (Loading)
Jan
Loading
1 min or
Feb
80 sec
March
average
April
May
June
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
July
Aug
Sept
Oct
Nov
Dec
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
TITLE:e.00401-AB20.04.01/04./WAREHOUSE OPERATION STUDY/CONTENTS:SUMMARY DATA REVIEW/LEAD DESIGNER:MANOLAS I. /DATE:12/10/2010
4.SUMMARY DATA REVIEW

4.1. REACH TRUCKS
max
Arrangement
Retrieval
Picking
Re-deposition
Ripening R.
min /
plt
Hours/
Day
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
1,34
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
1,34
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
2,70
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
1,89
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
hours
hours
hours
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
Total
Jan
Feb
March
April
May
June
July
Aug
Sept
Oct
Nov
Dec
max
4.2.ELECTRICAL PALLETE TRUCKS

max
IN
OUT
Arrangement
Retrieval
Picking (A)
Picking (B)
Cross Docking
Transshipment
Cross Docking (PZ
Picking (PZ)
Re-deposition
Ripening R.
min /
plt
Hours/
Day
3,10
58,24
9,9 13,4
3,10
36,43
2,2
0,49
3,30
0,49
2,00
1,94
Jan
Feb
March
April
May
June
July
Aug
Sept
Oct
Nov
Dec
10,19
32,67
9,4 13,1
16,4
19,5
22,4
23,1
9,88
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
2,74
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
3,13
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
hours
hours
hours
hours
hours
hours
hours
hours
hours
hours
hours
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
hours
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
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
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
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
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
1,37
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
1,37
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
2,05
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
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
Total
322,40
max
4.3. LOADING - UNLOADING

max
Loading
Unloading
Total
min /
plt
Hours/
Day
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
1,33
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
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
hours
Jan
Feb
March
April
May
July
June
Aug
max
Sept
Nov
Oct
Dec
TITLE:e.00401-AB20.04.01/05./WAREHOUSE OPERATION STUDY/CONTENTS:WEEKLY DISTRIBUTION OF WORK/LEAD

5.WEEKLY DISTRIBUTION OF WORK

Warehouse A
OUT
Average
14,8%
3.153
2.425
11,3%
3.192
12,7%
2 760
2.760
13 8%
13,8%
17,6%
2.711
Monday
Tuesday
Wednesday
Thursday
Friday
IN
3.110
2.337
2.160
3 073
3.073
4.721
Saturday
Sunday
3.932
2.543
3.546
2.560
21.875
20.348
Sum
IN
17,7%
12,1%
Monday
Tuesday
Wednesday
Thursday
Friday
Saturday
Sunday
Sum
Warehouse A & B
OUT
Average
IN
2.647
4.187
3.394
2 402
2.402
2.337
Warehouse B
OUT
Average
17,5%
1.803
22,7%
1.587
19,6%
1.576
1 328
1.328
14 7%
14,7%
1.711
15,9%
355
12
1.504
568
15.333
10.076
TOTAL STOCK
7,3%
2,3%
.O.
Monday
Tuesday
Wednesday
Thursday
Friday
5.757
6.524
5.553
5.475
7.058
4.956
4.012
4.768
4.088
4.423
15,8%
15,6%
15,3%
14,1%
17,0%
Monday
Tuesday
Wednesday
Thursday
Friday
15.059
18.505
10.220
10.452
15.721
8.288
8.674
8.641
8.214
8.477
14,8%
11,3%
12,7%
13,8%
17,6%
-1,0%
Saturday
Sunday
4.287
2.555
5.050
3.128
13,8%
8,4%
Saturday
Sunday
7.493
4.134
8.519
5.279
17,7%
12,1%
3,9%
37.208
30.425
81.584
56.092
Sum
Sum
so:
( 1 ) Warehouse A & B
1
Work distribution
Monday
Tuesday
Wednesday
Thursday
Friday
Non Working Saturday
days
Sunday
( 1 ) Warehouse A & B
( 2 ) Total Warehouses
15,8%
15,6%
15,3%
14,1%
17,0%
Work Distribution
25%
15,8% 15,6% 15,3% 14,1% 17,0%
13,8%
max
13,8%
8,4%
17,0%
8,4%
0%
-4,3%
-2,6%
-0,3%
0,6%
3,7%
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
6. OPERATING DATA FOR ELECTRICAL PALLETE TRUCKS

6.1.WEEKLY WORK DISTRIBUTION OF ELECTRICAL PALLETE TRUCKS
ELECTRICAL PALLETE TRUCKS
8-9
1
1
2
Incoming goods (IN)

Arrangement
Picking (A)
Picking (B)
Cross Docking
Transshipment
Cross Docking (PZ)
Picking (PZ)
p
Re-deposition
Ripening Rooms
Monday
Tursday
Wednesday
Thursday
Friday
Saturday
Sunday
Monday
Tursday
Wednesday
Thursday
Friday
Saturday
Sunday
1
1
1
1
8-9 9-10 10-11

5,4
5,7
8,0
5,4
5,6
7,9
5,2
5,5
7,7
4,9
5,1
7,1
5,8
6,1
8,6
4,7
5,0
7,0
2,9
3,0
4,2
8-9
Work / Period
9-10 10-11 11-12 12-1
2
2
2
1
2
2
3
3
2
2
1
2
2
1
1
2
2
2
3
2
1
3
2
2
1
2
2-3
3
3
2
1
2
3-4
2
1
2
2
1
1
Work / Day
11-12 12-1 1-2 2-3 3-4
7,5
6,8
5,0
3,3
3,2
7,3
6,7
4,9
3,3
3,1
7,2
6,6
4,8
3,2
3,1
6,7
6,1
4,5
3,0
2,8
8,0
7,3
5,4
3,6
3,4
6,5
6,0
4,4
2,9
2,8
4,0
3,6
2,7
1,8
1,7
Requiered number of vehicles

9-10 10-11 11-12 12-1 1-2 2-3
1-2
2
3
8-9
21%
1%
5%
6%
2%
4%
12%
46%
3%
1%
12-1
1-2
2-3
3-4
1,4% 2,7%
2,7%
2,7%
1,4% 2,7% 4,1% 2,7%
0,1% 0,1%
0,1%
0,2%
0,2% 0,2% 0,2% 0,1%
1,6% 1,6%
1,6%
0,0%
0,0% 0,0% 0,0% 0,0%
0,0% 0,0%
0,0%
0,0%
0,0% 2,1% 2,1% 2,1%
0,0% 0,3%
0,3%
0,3%
0,3% 0,3% 0,3% 0,0%
0,0% 0,7%
0,7%
0,0%
0,0% 0,7% 0,7% 0,7%
1,0% 2,1%
2,1%
3,1%
3,1% 0,0% 0,0% 0,0%
5,1% 5,1%
10,3%
1,4% 0,0%
0,0%
0,0%
0,0% 0,0% 0,0% 1,4%
1,5% 0,0%
0,0%
0,0%
0,0% 0,0% 0,0% 0,0%
10,3% 10,3% 5,1% 0,0% 0,0%
34,4 36,0 50,5

47,1 43,2 31,7 21,1 20,1
12% 13% 18% 17% 15% 11% 7% 7%
Average work distribution 100%

hours
45,0
44,2
43,3
40,2
48,2
39,2
23,9
9-10 10-11 11-12
Work Distribution
25%
18%
12%
17%
15%
13%
11%
3-4
7%
7%
2-3
3-4
0%
8-9
8,0
9-10
10-11
11-12
12-1
1-2
hours
58,2
3,3
13,6
18,1
4,4
10,5
32,7
131,0
8,0
4,2
284

Suggested number of neseccarry vehicles
Required number of vehicles
8
6
Utilization rate of vehicles

For the critical hour
For the critical day
For the critical week
Annually
143%
100%
85%
72%
Average operating time / vehicle
2.116
9
48
284
12.699
hours
hours
hours
hours
hours
6.2.OPERATIONAL COSTS OF ELECTRICAL PALLETE TRUCKS

The electrical power cost (Industrial cost terms) is:
0,10
/ kWh
The battery capacity for the electrical pallete trucks with hand wheel is :
The autonomy of vehicles with real working conditions are:
24
1.300
360 AH =
8,0 working hours, or Energy Cost:
The annual Maintenance cost of the vehicle (Service Contract) is:

The value of the battery is:
V x
and withstands for about
1.000
For each vehicle =
0,11 / working hour
loading cycles, equivalent to:
The annual operational cost is:

Battery
344
0,86 / shift
1.000
so:
Service
1000
8,6 kWh, or:
Energy Cost
228,6
1.573
For the total number of the vehicles =
9.435
The operational cost for each hour is:
0,74 /h
0,16 / working hour

The operational cost for each Pallete is:
Incoming goods (IN)
Outcoming goods (OUT)
Arrangement
Retrieval
Picking (A)
Picking (B)
Cross Docking
Transshipment
Cross Docking (PZ)
Picking (PZ)
Re
deposition
Re-deposition
Ripening Rooms
and for each Process:

0,038
0,038
0,006
0,006
0,024
0,017
0,017
0,025
0,126
0,122
0,034
0 034
0,039
1.599
926
88
51
428
563
133
265
989
4.074
204
116
TITLE:e.00401-AB20.04.01/07./WAREHOUSE OPERATION STUDY/CONTENTS:OPERATING DATA FOR REACH TRUCKS/LEAD DESIGNER:MANOLAS I. /DATE:12/10/2010
7. OPERATING DATA FOR REACH TRUCKS

7.1.WEEKLY WORK DISTRIBUTION OF ELECTRICAL PALLETE TRUCKS
Reach Truck
Work / Period
8-9
Arrangement
Picking
Re-deposition
Ripening Rooms
Monday
Tursday
Wednesday
Thursday
Friday
Saturday
Sunday
2
1
1
8-9 9-10 10-11

1,5
0,7
0,7
1,5
0,7
0,7
15
07
07
1,5
0,7
0,7
1,4
0,6
0,6
1,6
0,8
0,8
1,3
0,8
8-9
Monday
Tursday
Wednesday
Thursday
Friday
Saturday
Sunday
0,6
0,4
0,6
0,4
9-10 10-11 11-12 12-1

1
2
1
2
0,4
0,2
0,4
0,2
2-3
2
3-4
8-9
46%
26%
21%
7%
Work / Day
11-12 12-1 1-2 2-3 3-4 hours
0,4
0,4
0,4
0,4
1,1
5,8
0,4
0,4
0,4
0,4
1,0
5,7
04
04
04
04
10
57
0,4
0,4
0,4
0,4
1,0
5,6
0,4
0,4
0,4
0,4
1,0
5,2
0,5
0,5
0,5
0,5
1,1
6,2
0,4
0,2
1-2
0,4
0,2

9-10 10-11 11-12 12-1 1-2 2-3
0,9
0,6
9-10 10-11 11-12 12-1
1-2
2-3
3-4
0,0% 3,8%
3,8%
7,6% 7,6% 7,6% 7,6%
7,6%
8,7% 8,7%
8,7%
0,0% 0,0% 0,0% 0,0%
0,0%
10,7% 0,0%
0,0%
0,0% 0,0% 0,0% 0,0% 10,7%
7,0% 0,0%
0,0%
0,0% 0,0% 0,0% 0,0%
0,0%
9,7
4,6
26% 12%
4,6
12%
2,8
2,8 2,8 2,8
8% 8% 8% 8%
6,7
18%
Work distribution
26%
25%
18%
5,1
3,1
12%
12%
8%
8%
8%
8%
11-12
12-1
1-2
2-3
3-4
0%
8-9
2,0

2
2
9-10
10-11
3-4
hours
16,8
9,6
7,9
2,6
37
TITLE:e.00401-AB20.04.01/07./WAREHOUSE OPERATION STUDY/CONTENTS:OPERATING DATA FOR REACH TRUCKS/LEAD DESIGNER:MANOLAS I. /DATE:12/10/2010
7. OPERATING DATA FOR REACH TRUCKS

Annually
82%
39%
33%
29%
2
6
37
1.723
861
hours
hours
hours
hours
hours
7.2.OPERATIONAL COSTS OF REACH TRUCKS

0,10
/ kWh
48
For each vehicle =
2.400
Service
1500
Battery
258
1.000
Energy Cost
,
248,1
2.006
4.013
2,33 /h
Arrangement
Retrieval
Picking
Re-deposition
Ripening Rooms

0,053
0,052
0,052
0,105
0,073
2,30
2 30 / shift
0,29 / working h
23,0
23 0 kWh,
kWh or:
1.500
480 AH =

so:
V x
1.419
812
933
629
220
0,30 / working hour
OPERATION
STUDY/CONTENTS:OPERATING
DATA
FOR
ELECTRIC
PEDESTRIAN
TRUCKS/LEAD
DESIGNER:MANOLAS
I.
8. OPERATING DATA FOR ELECTRIC PEDESTRIAN TRUCKS

8.1.WEEKLY WORK DISTRIBUTION OF ELECTRIC PEDESTRIAN TRUCKS
ELECTRIC PEDESTRIAN TRUCKS
Work / Period
8-9 9-10 10-1111-12 12-1 1-2
Loading
Unloading
8-9
Monday
Tursday
Wednesday
Thursday
Friday
Saturday
Sunday
3
1
2
2
2
3
1
3
3-4
1
3
2-3
52%
48%
1,8
1,8
1,7
1,6
1,9
19
1,7
1,7
1,7
1,6
1,9
19
2,2
2,1
2,1
1,9
2,3
23
1,7
1,7
1,7
1,5
1,8
18
1,7
1,7
1,7
1,5
1,8
18
1,7
1,7
1,6
1,5
1,8
18
1,6
1,0
1,2
0,7
1,6
0,9
1,5
0,9
1,9
1,1
1,5
0,9
1,5
0,9
1,5 12,2
0,9 7,4

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

11,0 13,7 10,8 10,8 10,6
13% 10% 13% 13% 16% 12% 12% 12%
3-4 hours
1,4
1,3
1,3
1,2
1,5
15
14,0
13,7
13,5
12,5
15,0
15 0
3-4
Work distribution
25%
16%
13%
3
2
116%
94%
79%
56%
1.637
13%
10-11
11-12
12%
12%
12%
1-2
2-3
3-4
0%
3,0

Annually
13%
10%
8-9

8-9
1,8
1,8
1,7
1,6
1,9
19
8-9
Monday
Tursday
Wednesday
Thursday
Friday
S t d
Saturday
Sunday
Work / Day
9-10 10-11 11-12 12-1 1-2
2-3
2,3
15,0
88,3
3.273,1
hours
hours
hours
hours
hours
9-10
12-1
hours
45,8
42,4
88
OPERATION
STUDY/CONTENTS:OPERATING
DATA
FOR
ELECTRIC
PEDESTRIAN
TRUCKS/LEAD
8. OPERATING DATA FOR ELECTRIC PEDESTRIAN TRUCKS

8.2.OPERATIONAL COSTS OF ELECTRIC PEDESTRIAN TRUCKS
/ kWh
0,10
24 V x

1.100
240 AH =
1.000
For each vehicle =
Energy Cost
=
+
117,8
673
1.346
0,41 /h

Loading
Unloading

0,011
0,009
0,07 / working hour

Battery
225
0,58 / shift
330
so:
Service
330
5,8 kWh, or:
693
652
0,14 / working hour
DESIGNER:MANOLAS
I.
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. OPERATING DATA FOR WAREHOUSE STAFF

9.1.WEEKLY WORK DISTRIBUTION OF WAREHOUSE STAFF
WAREHOUSE STAFF
Work / Period
8-9 9-10 10-11 11-12 12-1 1-2 2-3 3-4
0,1
0,1
0,2
0,2
0,2
0,1
0,1
0,1
0,3
0,1
0,1
0,1
0,1
0,1
0,1
0,2
0,1
0,1
0,1
0,1
0,2
0,1
0,1
0,1
Pallete Trucks
Reach Trucks
Electric Pedestrian Trucks
Monday
Tursday
Wednesday
y
Thursday
Friday
Saturday
Sunday
8-9 9-10
8,8
7,8
8,6
7,7
8,5
7,5
,
,
7,8
7,0
9,4
8,3
7,7
4,7
8-9
Monday
Tursday
Wednesday
Thursday
Friday
Saturday
Sunday
6,8
4,1
10-11
10,5
10,3
10,1
,
9,4
11,3
9,2
5,6
Work / Day
11-12 12-1 1-2 2-3 3-4
9,6
9,4
7,2
5,5
5,9
9,5
9,3
7,1
5,4
5,8
9,3
9,1
6,9
5,3
5,7
,
,
,
,
,
8,6
8,4
6,4
4,9
5,3
10,3 10,1
7,7
5,9
6,4
8,4
5,1
8,2
5,0
6,3
3,8
4,8
2,9

9-10 10-11 11-12 12-1 1-2 2-3
8-9
69%
9%
22%

hours
64,8
63,7
62,4
,
57,8
69,4
16%
14%
9-10
11
10
7
3
Payed hours
113%
87%
73%
79%
2-3
3-4
12,4%
2,4% 1,1%
1,1%
0,7%
0,7% 0,7% 0,7% 1,6%
2,8% 2,1%
2,7%
2,7%
3,3% 2,6% 2,6% 2,6%
55,5 49,2 66,4

14% 12% 16%
11,5% 10,6% 7,8% 5,1% 4,9%
60,9
59,7 45,3 34,7 37,4
15% 15% 11% 8% 9%
15%
15%
11%
8%
9%
2-3
3-4
0%
Utilization rate of staff

F the
For
th critical
iti l day
d
Annually
22.420 h
1-2
8,4% 8,8%
12%
11 0
11,0
Permanent staff
Seasonal staff
12-1
25%
8-9
Suggested number of staff with simultaneous work

Required number of staff with simultaneous work
11-12
Work Distribution
5,2 56,5
3,1 34,4
3-4
9-10 10-11
11,3
69 4
69,4
409,0
17.694,6
hours
h
hours
hours
Productive hours
10-11
11-12
12-1
1-2
hours
284,0
36,8
88,3
409
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. OPERATING DATA FOR WAREHOUSE STAFF

9.2. WORK COSTS OF WAREHOUSE STAFF
Basic Salary of staff on average is:
1.000
Totally number of monthly salary per year:

Working cost / hour is:
overheat costs (insurrance, etc.)
53%
0,10
14
10,1
The off-works for each worker in the week are:

The increase because of non work days is:
so the cost per hour increases at
/h
the total number of staff is:
37,5%
9,8 Permanent staff
per the basic daily salary, and regards
29% of the hours,
11,2 / h
so :
The working cost of the Warehouse staff for the whole year is:
251.747
For the total staff:
The working cost for productive hour is:
ELECTRICAL PALLETE TRUCKS
REACH TRUCKS
ELECTRIC PEDESTRIAN TRUCKS
14,2
Incoming goods (IN)
Outcoming goods (OUT)
Arrangement
Retrieval
Picking (A)
Picking (B)
Cross Docking
Transshipment
Cross Docking (PZ)
Picking (PZ)
Re-deposition
Ripening Rooms
Arrangement
Retrieval
Picking
Re-deposition
Ri
Ripening
i Rooms
R
Loading
Unloading
0,736
0,736
0,116
0,116
0,461
0 324
0,324
0,324
0,486
2,415
2,343
0,649
0,743
0,321
0,319
0,319
0,640
0,448
0,381
0,316
30.617
17.739
1.681
974
8.193
10 775
10.775
2.538
5.081
18.937
78.008
3.897
2.230
8.665
4.960
5.700
3.841
1.343
23.992
22.575
/ kWh
TITLE:e.00401-AB20.04.01/10./WAREHOUSE OPERATION STUDY/CONTENTS:COSTS SUMMARIES/LEAD DESIGNER:MANOLAS I.

/DATE:12/10/2010
10.COSTS SUMMARIES
10.1. SUMMARY OF WORK DISTRIBUTION DATA
Total
To
Arrangement
Retrieval
Picking
Re-deposition
Ripening Rooms
Incoming - Arrangement
OUT (Transfer to Order Prepar.)
Arrangement
Retrieval
Picking (A)
Picking (B)
Cross Docking
Transshipment
Cross Docking (PZ)
Picking (PZ)
Re-deposition
Ripening Rooms
Loading
Unloading
Cost / Operation
Veh
hicles
Staf
aff Cost
Cost / Plt
0,3 0,05
0,4
8.665
1.419
10.084
0,3
0,3
0,6
0,4
0,7
0,7
0,1
0,1
0,5
0,3
0,3
0,5
2,4
2,3
0,6
0,7
0,3
0,3
0,4
0,4
0,7
0,5
0,8
0,8
0,1
0,1
0,5
0,3
0,3
0,5
2,5
2,5
0,7
0,8
0,3
0,3
4.960
5.700
3.841
1.343
30.617
17.739
1.681
974
8.193
10.775
2.538
5.081
18.937
78.008
3.897
2.230
23.992
22.575
812
933
629
220
1.599
926
88
51
428
563
133
265
989
4.074
204
116
693
652
5.773
6.633
4.470
1.563
32.216
18.665
1.769
1.025
8.621
11.338
2.670
5.346
19.926
82.082
4.101
2.347
24.686
23.227
251.747
14.794
266.541
0,05
0,05
0,10
0,07
0,04
0,04
0,01
0,01
0,02
0,02
0,02
0,03
0,13
0,12
0,03
0,04
0,01
0,01
Staff Cost Vehicles
=>
/ plt out
Unit Cost / Services
/ plt in
10.2. COSTS PER PROCESS
Incoming - Arrangement 1
1,06
06
Retrieval - Outcoming 0,40 0,36
Re-deposition 1,4
Picking 3,8 2,9
Cross Docking 2,9 2,2
Transshipment 0,5
Loading 0,4
Unloading 0,4 0,3
Ripening Rooms 1,3
Unit Cost / Plt
4,2
Unit Cost / Kg
0,004
Total
Cost /
Services
44.068
44
068
25.463
8.571
108.674
22.596
5.346
24.686
23.227
3.910
16,5%
16
5%
9,6%
3,2%
40,8%
8,5%
2,0%
9,3%
8,7%
1,5%
Total
STORAGE CALCULATION 2013

MODEL
Table of Contents
1. INTRODUCTION
1.1 General assumptions Procedures specification
1.1.1
1.1.2
Catgories of Services
Stock Handling Activities
1.2 Task distribution Facility resources.

1.2.1
Personnel - quipment
1.3 Calculation parameters

1.3.1
1.3.2
Distances covered
Activity parameters
1.4 Results - Total Data / Resource / Activity
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: info@ibls.gr / Web: www.ibls.gr
3
4
7
7
8
8
9
11

MODEL
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
TECHNICAL COMPANY

MODEL
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
TECHNICAL COMPANY

MODEL
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
Quantity receipt per pallet
Homogenous pallet weighing
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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MODEL
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.
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]
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]
TECHNICAL COMPANY

MODEL
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]
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]
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:]
TECHNICAL COMPANY

MODEL
he loading of pallets onto trucks
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).
TECHNICAL COMPANY

MODEL
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
TECHNICAL COMPANY

MODEL
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, openclose 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
TECHNICAL COMPANY

MODEL
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
8,11,14,15,16,17,18,21,24]
rider
seat
pallet
trucks
Activity
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
10
TECHNICAL COMPANY

MODEL
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].
11
TECHNICAL COMPANY

MODEL
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
12
TECHNICAL COMPANY

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AB20.

04 STORAGE CALCULATION MODEL & CAPACITY

I. Manolas / Technical Director

Stock (Drive in)

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

WAREHOUSE OPERATION STUDY

BASIC DATA OF THE WAREHOUSE

PRODUCT HANDLING & CALCULATION DATA

TIME CALCULATIONS OF GOODS TRANSFER PROCESSES

SUMMARY DATA REVIEW

WEEKLY DISTRIBUTION OF WORK

OPERATING DATA FOR ELECTRICAL PALLETE TRUCKS

OPERATING DATA FOR REACH TRUCKS

OPERATING DATA FOR ELECTRIC PEDESTRIAN TRUCKS

OPERATING DATA FOR WAREHOUSE STAFF

1.BASIC DATA OF THE WAREHOUSE

Stock (Drive in)

Stock (Drive in)

And order preparation packing room and loading

The total area is

1.2. WAREHOUSE'S ANNUAL HANDLING OF GOODS

1.BASIC DATA OF THE WAREHOUSE

Citrus Fruits (out)

With an average residence

Indicated values of 2001

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

2.PRODUCT HANDLING & CALCULATION DATA

A) For storage stocks (dense and short)

2.2. MAXIMUM DAILY INCOMING GOODS HANDLING OF THE CENTER

192 260 325 388 449 506

9 111 103 119

129 192 229 277 346 387

Unloading (Plts in)

97 115 131 146

276 374 469 561 648 732

289 393 493 589 681 769

2.3. MAXIMUM DAILY OUTCOMING GOODS HANDLING OF THE CENTER

Picking (plts in)

Vol. increase of Plts due Picking

Picking from High Dense storage

159 153 148 144 342 340

207 199 192 187 444 442

and from Low Dense

Exit from storage rooms (Plts in)

Loading (Plts in)

41 111 177 240 123 179

391 482 571 656 737 815

69 148 224 298 192 259

992 1001 1007 1009 1009 1006 1000

279 299 318 337 614 631

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

2.PRODUCT HANDLING & CALCULATION DATA

Average batch product handling

Average rest of Block

plts at the high dense k

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

3. TIME CALCULATIONS OF GOODS TRANSFER PROCESSES

Withoutt Loading Unloading

The average distance per room of internal transfer vehicles is:

The vehicles are moving with a average speed ( U ) km/hr of

The vehicles per trip forced into () stops

stops, time loss / stop t1

The opening of the doors will be done per

10 plts at High dense k

Storage Calculation Model & Capacity Utilization

Storage Calculation Model & Capacity Utilization