Ex 1 – B

System size:

NL max = 18 levels

NC max = 85/1.8 = 47 columns

NA min = 14000/(2*2*47*18) = 5 aisles

NC real = 14000/(2*2*18*5) = 39 columns

SC real = 2*2*47*18*5 = 14040 PLs

System design:

RL = 39*1.8 = 70.2m

RH = 18*1.6 = 28.8 m RFW = (1.3*2+1.4)*5 =20 m

System configuration:

SL = RL = 70.2m

SH = (NL-1)*H = 27.2 m Y i/o = 2*1.6 = 3.2m

Cycle time and TC:

P1 = (14.04m; 18.14 + 1.07) P2 = (46.8; 5.44 + 1.07)

T(I->P1) = max {6.69s; 20.01s} T(i->P2) = max {22.29s; 4.14s}

AVTscc = 20.01+22.29 = 42.3s

AFTscc = 50s

ATscc = 92.3s

T(P1->P2) = max {15.6; 15.88}

AVTdcc = 58.18s

AFTdcc = 86s

ATdcc = 144.18s

TC = NA* [3600*(0.5*0.2 + 0.8)]/(0.2*92.3+0.8*144.18) = 121.07 PL/h

Automated vs traditional costs:

automated WH:

cost of rack = 80*14040 = 1123200€

S/R machines = 180000*5 = 900000€

TV = 1000000/(1+0.05)^6 = 746215.40€

HC = sum (from 1 to 6) of [((0.2*121.07)+15)*8*252]/1.05^6 = 79055.42/1.05^6 = 401260.97€

TOT cost = 3170676.67€

Traditional WH:
TC picker = 0.9*3600/200 = 16.2 cycle/h or 16.2 PL/h

# of pickers = 110/16.2 = 7 pickers

Tot TC = 113.4 PL/h

HC =( (0.2*113.4)+15)*8*252)*7/1.05^6 = 531740.16/1.05^6 = 268948.91€ the investment is worthwhile

Shape factor:

SF = SV-3.2/sh / SH/sv = 0.89

If add one s/r machine the TC increases proportionally

Ex 2

SUT = 50s

RT = N*(RTL + RTP+NPL) = 60s

Li(N) = 13.5v

V = 5.298 Li(N) = 71.53m

f = sum (from j=1 to J=a/2) of j*(Pj ^N – Pj-1^N)

f = 4.69 + 2.42 + 1.16 + 0.49 + 0.19 +0.06 +0.01 = 9.02

Le(N) = 85.23 m

ETT(N) = 156.76/1.2 = 130.64s

PT = 130.64 + 50+ 60 = 240.64s

Class-based policy:

AI%(A) = 51.7% => # dedicated aisles = 800/200item*rack*2 = 2 AI = 25.85%

AI%(B) = 36.73% => # dedicated aisles = 2400/200item*rack*2 = 6 AI = 6.12%

AI%(C) = 11.56% => # dedicated aisles = 4800/200item*rack *2= 12 AI = 0.9634%

V(A) = 2*(1-(1-0.2585^6)) = 1.67

V(B) = 6*(1-(1-0.0612^6) = 1.89

V(C) = 12* (1-(1-0.009634^6)) = 0.68

V = 4.24 aisles

Li(N) = 13.5*4.24 = 57.24m

f=6

Le(N) = 55m

ETT(N) = (55 + 57.24)/1.2 = 93.54

PT = 93.54 +60+50 = 203.53s

If we introduce the return policy the best one is (iii)

RT batching:

RT = (Nb*RTL) + (NPL*RTP*N) = (36*4) + (2*3*60) = 504s

Nb = 60*(1-0.4) = 36

Ex 3

13) SSrw1 = 45.83 + SScw

SScw = k* sqrt ((7/5)* 22^2 + 95^2*(0.4/5)^2) = k*27.11

K = 0.01*550/27.11= 0.2028 => k=0.5

SScw = 0.5*27.11=13.55

TOT SS = 45.83 +13.56 = 59.39 PLs

14) ½ * 205*1 + ½ *550* 1 + ½ *95*1 = 425 PLs

15) ½ *205*2 + ½ *95*2 +550* ½ = 575 PLs

16) ITS non le abbiamo fate

17) RW1/2/3 =N* k* sqrt ((7/5+4/5+1)* 19^2 +0) = k* 33.19

K = 1.2

Tot SS = 1.2*33.99*3 = circa 132

18) 575 PLs