The organization’s masterplan is based on the following principles:

• Optimal flow of vehicles and pallets between buildings at the site (ingress/egress, plants and warehouses)

• Adjusting the optimal storage and handling methods

• Maximum utilization of the area – leaving reserves for growth

 

A typical project includes:

 

Stage 1 – survey of needs, collection and analysis of current-situation data:

 

• Area and height balance

  • Description of activity in the compound

  • Description of activity in the area around the compound

    • Production

    • Operations

    • Storage (according to storage temperature)

  • Compound height

• Defining the complexity of moving existing compounds to other locations within the site

  • Infrastructures

  • Compounds not intended to be moved

• Defining in principle the possibility to increase the compound in terms of height dimension

• Changes in existing compounds

  • Compounds which are intended to leave the site

  • New activities to be introduced into the site (details of the activities, required areas, scopes of traffic in and out of the compound, etc.)

• Infrastructures

  • Infrastructures in the compounds

• Capacities, outputs, and future design of the compounds

  • Warehouses

    • Current warehouse capacity

    • Current warehouse occupancy

    • Forecast of annual growth in required capacity (due to increase in the scope of activity)

    • Maximum future planning of the warehouses based on current warehouse capacity

    • Local alternatives of increasing warehouse capacity – how much can future planning be increased accordingly

  • Plants

    • Current no. of shifts

    • No. of shifts which can be operated in order to increase output, if required.

    • Current plant output

    • Plant's maximum possible output

    • Annual growth forecast in plant outputs (due to increase in scope of activity)

    • Future planning of the plants based on the existing layout

    • Alternatives of increasing the output based on the existing structure – how can future planning be increased accordingly?

• Picking warehouse

  • Current balance of areas according to storage temperature

  • Current number of SKU by storage temperature

  • Picking locations

    • Number of SKU for which picking location of an entire pallet is required

    • Number of SKU for which picking location of half a pallet is required

    • Number of SKU for which picking location of a deck is required

  • Stock distribution (pallets) by SKU

  • Pallet movement volume distribution by SKU

  • Distribution of picking lines by SKU

• Site movement balance

  • No. of incoming and outgoing pallets to/from the compound on an average/peak day

  • No. of incoming and outgoing trucks to/from the compound on an average/peak day

  • No. of internal movements between on-site compounds – details of the method of internal handling at the site (trucks / forklifts)

• Links between the compounds

  • Definition of links between compounds

  • The scope of daily traffic between compounds

• Operating areas (receiving, storage, picking, assimilation of ready shipments, etc.)

• Manpower in the compounds

  • Management

  • Production

  • Logistics

• Office program per each compound

 

Preparing a Dada Summary Report, which will form the basis for the planning and design – this will be presented to you for your approval

 

Stage 2 – Alternative matrix definition:

 

• Defining technological alternatives for pallet storage

  • Expansion of the existing automated warehouse

  • Building a new automated warehouse

    • Regular automated warehouse (cranes)

    • Automated pallet multi-shuttle warehouse (elevators, carriers and shuttles)

    • Satellite-integrated crane automated warehouse

• Defining alternatives for the picking warehouse layout

  • Retaining the existing picking warehouse

  • A new picking warehouse integrated with AGV automated replenishment

  • Additional alternatives defined by us

• Defining placement alternatives for compounds on site

For each alternative, the following will be prepared:

• Drawing of the alternative

• Flowchart of truck and forklift traffic at the site

• Estimate of establishment costs

• Estimate of operating costs

• Implementation timetable

 

Stage 3 – Comparing between alternatives and making a recommendation:

 

• Preparing a summarizing presentation of the masterplan

The presentation will include an economic comparison and a qualitative operating comparison between the matrix of alternatives (positioning / layouts / technologies), and a recommendation of the optimal combination of alternatives for you, as well as the overall layout

• Transition to the implementation stage