TAB 4 QUOTE ENGINEERING BLDG 8-1 FINAL NAVSUP.pdf

Preferred Alternative 2 Conceptual Layout

Finalization

Prepared for: NAVSUP December 6, 2018

• Assumptions

• Alternative 2 – Side Loader Truck Design

• Plan

• Elevations

• Inventory Analysis

• Over Weight Items

• Inventory Profile by Rack Type

• Inventory Capacity Extrapolation

• Pallet Weight Considerations

• Side Load Material Handling Equipment

• Minimum Turn Radius

• Layout Zoning Development

• Labor Productivity

• Estimated Equipment Costs

• Next Steps (NAVSUP)

• Appendix

Agenda

• 3,274 dimensional sampling is indicative of the full population of crates – previously reviewed

• 100% inventory selectivity desired to support audit readiness

• Floor storage will be relocated to other buildings. Staging in layouts not included in capacity counts.

• Small crates can be store two-per-pallet or two-per-locations

• Building clear height = 19’-0” BOS

• Top of Load (TOL) = 18’-0”

• All storage locations can support 5,000 lbs

• All storage locations will be fitted with bar grate or other heavy duty decking

• All MHE can lift 5,000 lbs to top level

• In-rack fire sprinkler system not required

• Rack opening heights and number of levels designed to create aisles with single height rack profile where possible

• Example: “All rack in Aisle #10 has profile that is 8 levels high sized for 17” material height”

• Floor design is sufficient to support racks – Floor capacity, soil bearing capacity, and underground heating tunnel impacts to be verified

Assumptions

Alternative 2 Layout and Elevation

Alternative 2 Layout Plan

Inventory capacity @ 100% utilization: 7,486 crates

Alternative 2 Rack Elevations

Inventory Analysis

• Loads over 5,000# will be relocated to other facilities

• Within the 3,274 sampling, 7 crates were identified as greater than 5,000#. This would extrapolate out to approximately 21 over-weigh crates on building 8.

• Identified over-weight crates:

Assumptions

NSN Location L (Rack Width) W (Rack Depth) H Weight Pallet Type Item Type Handling

Side Built in Pallet Locator che

K5 157 31 34 6,380 STRINGER CRATE L Y 96-51083 96-

K9 65 65 25 5,556 S C L Y CHE07676 CHE

H1 43 34 31 8,980 CRATE L Y CHE6937 CHE

97-13635 A22 48 34 62 7,650 Stringer Crate Length Yes 97-13635 97- 97-13635 A22 48 34 62 7,650 Stringer Crate Length Yes 97-13635 97- 97-13635 A22 48 34 62 7,650 Stringer Crate Length Yes 97-13635 97- 97-13635 A22 48 34 62 7,650 Stringer Crate Length Yes 97-13635 97-

Inventory Profile by Storage Media Type

• Storage profiles were developed for rack media types and elevation profiles. Rack type is coded with; rack depth, single-wide/single-deep, cantilever/pallet rack, and load heights for each rack profile.

• The inventory was modeled by rack type to match the proposed rack layout.

Accounting for double crates per storage position where possible, a 100% utilization storage capacity of 7,486 is achievable.

• Floor Storage was excluded from this building. Floor storage locations shown on layout are not considered in capacity counts.

Rack Type Number of Levels 60 CTLVR-25_48h 4

60 CTLVR-89h 2 SD 40 Rack-17h 8 SD 40 Rack-25h 6 SD 40 Rack-48h 4 SD 40 Rack-89h 3

SW_SD 60 Rack-25_48h 5 SW_SD 60 Rack-89h 2

Inventory Profile by Media Type Analysis

• At 7,486 inventory level, the following rack elevation profiles and effective rack bays will be required.

Pallet Rack Weight Considerations

Pallet Rack Weight Considerations

• We found that the smaller crates sizes have lower average weights and for the 17" bracket, where they would be stored 8 high, also has a lower max weight.

• If you were to design for maximum weight stored in every storage location, we would see a peak weight of 60,000# per upright frame and therefore 30,000# per post. This is unrealistic, in-that we do not have sufficient inventory to randomly fill more than one level throughout the rack, and, the average weight is significantly lower than the max. – this is exhibited in column ‘Frame Loading (Levels @ Max)’ .

• Designing the rack for the average weight would not account for a max crate condition. although, rack companies can perform there calculations with average weights.

• To create a more realistic loading conditions, one could assume that the rack had one of the levels filled with the max weight crate, on both sides of the upright, and the balance of the storage levels filled with average weight crates. This is exhibited in column ‘Frame Loading (Levels Avg + 1 Max)’ below.

• Then, the worst case scenario for cantilever rack would be 18,788#, call it 20,000# with rack loading, distributed over 60” long legs, approximately 10” wide, laying on the floor.

• Then, the worst case scenario for pallet rack would be 14,754#, call it 16,000# with rack loading, distributed to 2 posts, equaling 8,000# per post.

• Rack posts are typically fitted with 4”x6”, 5”x7”, 8”x8”, 10”x10” foot plates that distribute the imposed loads onto floor and provide better anchor placement to meet seismic design calculation requirements. Size of the foot plates can be some-what dictated to help distribute point loads onto the floor.

Side Load Material Handling Equipment

• Side Loader Trucks

• 8’-2” aisle width requirement

• Accommodates 60” deep loads

• Accommodates NAVSUP requirement of 260” wide loads

• Single sided aisle access

• Requires rail guided storage aisles

• For 260” loads, 28’ cross aisle required

• For 150” Loads (truck length) 20’ cross aisle required

• Available in Electric from Raymond

• Model 9400

• Available in LP and electric from CombiLift

• Model 10000GT – LPG

• Model 12000GTE – Electric

• Guide rollers 5” above floor on truck to accommodate ramp grade

• Crab steer option helps operator maneuverability

• Requires in-aisle guide rails 8” high with tapered entry guides

MHE Side Load Equipment

Side Load Truck Base Models

MHE Side Load Equipment

CombiLift C 11000 GTE

CombiLift C 10000 GT

Raymond 9400

MHE Equipment Requirement Combi-Lift

236” (19.6’) Cross aisle required with 150” x 60” load 329” (27.4’) Cross aisle would be required with 260” x 60” load – Layout developed to store long crates within main aisle: no turns required

Layout Zoning Development

CANTILEVER

4 HIGH

< 96” WIDE

19%

CANTILEVER 4 HIGH > 150” < 260” WIDE

PALLET RACK

4 HIGH

< 96” WIDE 22%

PALLET RACK

3 HIGH < 96” WIDE 4%

PALLET RACK

8 HIGH < 96” WIDE 32%

PALLET RACK

6 HIGH < 96” WIDE19%

PALLET RACK 60” DEEP 5/2 HIGH < 48” WIDE 4%

• Inventory split by area approximates velocity zonig split

• Methodology:

• Assume all inventory has the same turns (velocity)

• Create high frequency by area by creating high and low storage density areas

• Locate smaller crates closer to receiving and shipping to minimize travel and increase access density within an area

• Locate cantilever rack in south chamber to facilitate handling from ramp

• Allows receipts of long stock from apron or Building 7

• Long stock greater than 150” (<260”) stored in main aisle – no turns required

• 8 High pallet rack in center chamber closest to new bridge from Building 7 and shipping

• 2, 3, 4, & 6 High pallet rack in north chamber, further from receiving and shipping points provides less travel frequency to areas requiring longer travel distances

Labor Productivity

Reasonable Expectancy Methodology & Findings

• Align Reasonable Expectancy with current operation:

• Identify tasks required to perform current operation

• Identify frequency and travel distances – assumes the need to move 40% of zone at two crates per move, to acquire picked crate

• Calculate current productivity rate

• Develop Reasonable Expectancy for future operation, based on current operation RE

• Identify new tasks, eliminate un if needed

• Adjust task frequencies and travel distances as required. (remove digging process to acquire crates)

• Picking Results:

• Current productivity: 45.8 minutes per cycle = 1.3 crates per hour

• Future productivity: 13.8 minutes per cycle = 4.4 crates per hour

• Productivity gain: 3X

• Labor effort reduction: 69%

• Weighted Average Productivity Calculation

• Assume 90%/10% split in building 7/8

• Weighted average pick rate may decrease from 15.0 to 11.8

Anticipated Layout Optimization Impact on Productivity

• Weighted Average Productivity Calculation

• Assume 90%/10% split in building 7/8

• Current weighted average pick rate for the combined buildings: 15.0 minutes per pick

• Weighted average pick rate can not be reduced below building 7 rate

• Calculations assume 90/10 split, 45.8 minutes for building 8 picks, resulting in an 11.6 minute average pick for building 7

• Holding building 8 picks at 11.6 minutes, setting building 8 to the future 13.8 minutes per pick, results in 11.8 weighted average minutes per pick between both buildings

• Does not include new bridge optimizations or increased shipping from building 8 shipping dock

Current Conditions

Future Conditions

Next Steps (NAVSUP)

Next Steps Open Engineering Tasks- NAVSUP

• Aisle width requirements can vary based on MHE supplier.

• Rail guidance design height will vary based on MHE supplier.

• Main aisle width will vary based on turn radius of MHE equipment procured.

• In-rack sprinklers will impact proposed rack elevations. – Not required with ESFR System per Corp input.

• Blind aisles need to be reviewed for personnel fire egress.

• Fire egress door locations and paths need to be reviewed to confirm compliance with fire safety codes.

• Firewall doors appear to be manually operated. Automatic temperature links could allow doors to close automatically. Typically personnel egress doors are provide adjacent to aisle-size fire doors.

• Will a personnel door be provided adjacent to the new bridge entrance from building 7? If so, rack will need to be adjusted.

• Floor capacity. Concrete thickness, strength, and soil bearing capacity analysis needs to be performed to identify racking point loads that can be supported. Rack designs can be augmented to mitigate some lower floor capacities if requirements are identified. Subfloor heating tunnels need to be precisely located and mitigated.

• Point loads imposed on the floor by the rack will need to be confirmed.

• Vents located along perimeter walls need to be identified, as they will interfere with the proposed rack system.

• Lighting will need to be provided within each of the proposed aisles. Emergency egress lighting may be needed to meet code. With the number of aisle, these can be included in the overhead lighting layout design. Exit door signage may also be needed.

• Heater/air rotators will need to be rotated or moved. Actual flue location will need to be identified to determine how the air unit should be rotated. The layouts make an assumption to move the unit into a row of rack, but based on the flue location, they may need to be located in an adjacent row of rack. Additional clearance requirements beyond the bollards would need to be identified. – Already scheduled for replacement

Next Steps Open Engineering Tasks- NAVSUP

• Single row of rack along main aisle extends a few inches into the doorway main defined aisle. Is this acceptable? Should the back of the rack facing the main aisle be covered with cargo netting to prohibit falling loads that may be pushed through from the opposite side? Can pallet stops be provided in-lieu of netting?

• Radon pipes will need to be relocated. – Facilities indicated that they can perform needed modifications

• We have not provided sanitation aisles along the perimeter walls (rat runs).

• Dehumidifiers will need to be protected and one may need to be moved if possible.

• Operating procedure will need to be determined.

• Where is product unloaded?

• Where is it “received”?

• How is it transported through Building 8?

• Is it transported and dropped in staging or subsequent put away?

• How will inventory by location be kept?

• How will empty locations be identified and assigned prior to physical put away?

• How to manage multi-wide location allocations in cantilever rack and pallet rack as “occupied” or “open”?

• Aisle and location number scheme?

• Location labeling requirements. Human readable only? Barcodes to facilitate system scanning?

• License plate numbers (LPN) labels applied to every crate. Bar code or serial number only would provide unique identifier for crate and receipt information.

• Training requirements for the operators to identify how to slot materials in the rack.

• Allocation of space adjacent to offices. Floor storage shown is not included in the building capacity. Battery charging will not be needed for Combi-Lift side loader truck if LP gas is procured.

• LPG tank storage would need to be staged near Building 8 for replenishments.

• Electrical panels near transformer room should be guarded to maintain safety distance from product.

• Unconstrained main aisle widths can be created in the proposed layout by eliminating storage rack, but reducing capacity

Appendix

Attachments (Sent under separate cover)

• AutoCAD file

• PDF of Layout and elevations

• Collected cate data

• Data analysis workbook – working copy

• PDF brochures from vendors