WARHOUSE_PLANNING.pdf - Simco Consulting

WHO IS SIMCOWHO IS SIMCO

Simco is one of the most important and independent Italian consulting companies.Since 1981, when it was established, Simco has been developing over 1.800 projects for more than 450

f ffCustomers of different sizes and sectors.Our mission is to combine expertise and technology to analyze and improve processes, motivate andqualify human resources in order to control and develop the overall performance of the company.Our method does not provide standard solutions but offers a tailored approach modeled on the realOur method does not provide standard solutions, but offers a tailored approach, modeled on the realneeds of the customer and inspired to practicality and innovation.Particular attention is given in the use of advanced tools in order to make the results of projects certifiedby sophisticated analysis; Simco can develop a relationship that starts from the definition of improvementy p y ; p p pand change actions, and can may come up to assistance during implementation, to facilitate and monitorthe achievement of objectives.

Average yearly turnover(2001‐2011)€ 1 600 00059%

27%

14%

Warehousing projectsOther Logistic Projects

€ 1.600.000.59% g jTraining

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SIMCO partners:Cesare Marco Diego Alberto

Cernuschi Cernuschi Giometti Zampieri

Our Senior Consultant:Senior Consultants boast an experience of about 20 years in the logistics sector; their approach isinnovatory and they can profit from the experience of more than 30 years of projects. Each time wetackle Customers problems, we do it as carefully as if they were ours.Simco staff is made of permanent employees and the use of Free Lance is extremely limited ThisSimco staff is made of permanent employees and the use of Free Lance is extremely limited. Thisallows us to invest in the systematic and steady training of our resources and provides the Clientwith a point of reference in the conduct of the project and the continuation of the relationship.Simco is certified Vision 9001:2008 (certificate n° 9175 SMCO ‐ first issue 1998).

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( )


Simco organizes inter‐company and in‐housecourses and workshops (about 40 coursescourses and workshops (about 40 coursesabout logistics in the catalogue).

A h k W k h i l dA shot taken at our recent Workshop entitled

“Automation in warehousing and handling: how and when is it convenient?”

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THOSE WHO HAVE CHOSEN SIMCOTHOSE WHO HAVE CHOSEN SIMCO

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BEST KNOWN COMPANIES AMONG SIMCO’S CUSTOMERS

ALSTOM, AGUSTA WESTLAND, AUCHAN, AUTONEUM, BAYER,BASF, BINDA, BOHLER, BTICINO, CARREFOUR, COCA‐COLA,, , , , , ,COOP ITALIA, CORMAN, DENSO, DIESEL, DUCATI, FACET,FIAMM, FIAT AUTO, FISCHER, FLINT GROUP, FOPPAPEDRETTI,FRESENIUS M.C., G6 RETE GAS, GEFRAN, GE HEALTHCARE T.,GIORGIO ARMANI, IND. CARTARIE TRONCHETTI, IVECO,JOHNSON DIVERSEY, JOHNSON & JOHNSON MEDICAL, KONICAMINOLTA, LEGRAND, LEROY MERLIN, LEVI STRAUSS, LINDT &SPRUNGLI LEROY MERLIN L’OREAL LOTTO LUXOTTICASPRUNGLI, LEROY MERLIN, LOREAL,, LOTTO, LUXOTTICA,MERCK SHARP & DOHME, NOVARTIS VACCINES, PANASONIC,PIONEER, PONTI, ROCHE DIAGNOSTICS, SAMSUNG, SNAMRETE GAS, SOL, STAPLES, SUBARU, TEMPUR, TEVA, THUN,

Simco has developed many projects and consultancies

RETE GAS, SOL, STAPLES, SUBARU, TEMPUR, TEVA, THUN,TRW, VOLKSWAGEN.

opera ng in interna onal se ngs in Austria, Bulgaria, Croa a, France, Greece, Malta, Poland, Spain and Switzerland. Simco’s average revenue generated by each customer: about € 130.000

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PRESENTLY WE ARE WORKING FOR:PRESENTLY WE ARE WORKING FOR:

• AUTONEUMA t ti I d t l i f t t i ti

• GIORGIO ARMANI Fashion – Detail design and management of logistic

Automotive Industry - analysis of transport organization (intra-plants haulages)

• CAMEEngineering – Feasibility Report for Materials and Components warehouse

g g gequipment purchasing for the hanging garments and accessories warehouses of Baggiovara DC.

• LEROY MERLINDIY– assistance to new WMS implementation activities

Components warehouse• DENSO THERMAL SYSTEM

Automotive Industry– Detailed Design and Project Management for a New Automated Distribution Center.

• DUCATI

• L’OREALCosmetics - Detail design, management of logistic equipment purchasing and Construction Project management for a new automated warehouse.

Motorcycle Industry – evaluation of 3PL performances and preparation of new Tender Documents

• FACETAutomotive Industry – executive project for

t li ti f Fi i h d P d t h

• SEAC SUBDiving sector – Warehouse construction project

• SORMAexternalization of Finished Product warehouse

• FISCHER ITALIAFixing Systems – FP Warehouse Reengineering.

• FONTANA PELLETTERIE

Mechanical – Feasibility Report for Distribution warehouse

• SVIMAPharmaceutical Distribution – Feasibility Report for

Luxury fashion – detailed design and coordination, for construction of leather and accessories warehouse

y pStorage and Material Handling systems for finished products warehouse

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OUR AREAS OF INTERVENTION

Optimization / re‐design of distribution network Optimization / re‐design of distribution network

Warehouse design Design of new warehouses / DCs Re‐layout of existing warehouses / DCs Support to outsourcing projects

Demand and Inventories optimization

l

Support to outsourcing projects

Dynamic simulation

Business Intelligence solutions

Business organization

Training

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WHY CHOOSING SIMCO?WHY CHOOSING SIMCO?

Company’s

Consolidated know‐how about

structure, end‐to‐end experience, methods and

warehousing and

transportation

Consolidated

tools

Consolidated know‐how

about real‐life situations (sw,

3PLs etc )3PLs etc.)

Concrete implementations, not ideal solutions:f l ti t i l t ti d ti i t

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from general conception to implementation and continuous improvement

WAREHOUSE LOGISTICS DESIGNOur approach

AuditWe identify the strengths and weaknesses of the warehouse and define possibleinterventions highlighting the expected benefits, the prerequisites for theirimplementation, and any risks, time and resources required.

Feasibility ReportDefines the technological and organizational strategic options, to eliminate theweaknesses and to achieve levels of excellence, with regard to efficiency, accuracyd d f l l h h l d d dand service. Identifies alternative solutions, which are analyzed and compared

defining the obtainable results, investment and operating costs, ROI, “pro’s &con’s” and implementation time.

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WAREHOUSE LOGISTICS DESIGNOur approach

Detail ProjectI i h l i l d i h f ll f h h iIt is the analytical design phase of all components of the warehouse, to issuedrawings and specifications necessary and functional for the launch of tenders.

Management of construction phaseIn support to the Customer, it offers technical assistance to the correct management of contracts, as far as technical contents and project schedule g , p jissues are concerned. Project management is carried out for logistics supplies, as well as it may include on site supervision of the building yard, staff training and assistance in testing , start‐up and commissioning.

Periodic monitoring of the efficiency (post‐auditing)After the start‐up of the warehouse, the results actually achieved are monitored toAfter the start up of the warehouse, the results actually achieved are monitored to assess any deviations from the goals that were set and to identify the reasons for the deviation. The scope is to establish new goals, by removing the problems with the logic of "continuous improvement".

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g p

FEASIBILITY REPORTScope of work

SCOPE: to identify carefully and suggest the best possible option to be implementedSCOPE: to identify carefully and suggest the best possible option to be implemented

• Collection and analysis of current data• Analysis of current logistic processesDESIGN DATA

D fi iti f lt ti l ti f

• Analysis of current logistic processes• Definition of projection factors

DESIGN DATA

FEASIBILITY REPORT

• Definition of alternative solutions for: Storage and material handling systems Processes, procedures, organization HW&SW architecture

• Definition of the criteria for the comparison

DEVELOPMENT OF ALTERNATIVE SOLUTIONSREPORT

• Estimate of investment costs (15% accuracy) and costs/benefits analysis

Definition of the criteria for the comparison of alternatives

accuracy) and costs/benefits analysis• Comparison of alternative solutions• Recommendation of the optimal solution• Final Report

RECOMMENDED SOLUTION

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FEASIBILITY REPORTThe recommended project team

COMPANY MANAGEMENTStrategical trend long term forecast “basic” choicesStrategical trend – long term forecast ‐ basic choices

CompanyProject Core Team

ion mod

els

al aspects

e & costs

L i ti C lt tOrgan

izat

Technic a

Sche

dul

Confrontation onproject issues

Logistic ConsultantProject Team

Company’s other staffRESULTS

Company s other staff•process owners•IT, QA, validation, purchasing, sales, marketing, production, etc. O

perativ

e bu

sine

ssda

ta

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production, etc. O

FEASIBILITY REPORTData collection and elaboration

Articles and load units

• SKU Master Data

Inventories• process requirements• service level requirements

•cubic per SKU•load units per SKU•seasonality patterns•trends

• load unit size and cubic• packaging size and cubic• weight / fragility• shelf life

PROJECTIONS

q• design targets

•ABC analysis

DATA BASE

PROJECTIONS Flows

SKUs

lines and qtys out & in

DES

•picking lines per SKU•picked items per SKU•shipped boxeshi d l d i

DATA BASENot only averages!

lines and qtys out & in

orders profile

distribution channels

stock management

SIGN D

•shipped load units•orders (by channel)•orders profile•ABC analysis

li

• Personnel (number, mansion, qualification, costs,..)

• Productivities of main logistic processes (picked lines or pz./ h)

stock management

manufacturing

level of service

new assortment

DATA

•seasonality patterns

Manpower, productivity and workflows

In & Out flows

p (p p / )• Time & Motion studies new customers

14

and workflows

FEASIBILITY REPORTExample of inventory analysis

Comp. Descrizione N° Codici % progrN° Medio Pallet in

Giac.% progr pallet x cod

98 MATERIALE VARIO 59 3% 3% 2.018 21,7% 21,7% 34,204, 05, 10 BULK e PF per exp 251 14% 18% 1.260 13,5% 35,2% 5,020, 21, 22 ASTUCCI 346 20% 38% 937 10,1% 45,3% 2,7

01 ECCIPIENTI 74 4% 42% 921 9,9% 55,2% 12,445 CONFEZIONI MULTIPLE 57 3% 45% 797 8,6% 63,7% 14,097 PALLET 4 0% 45% 543 5,8% 69,6% 135,8

06, 07, 0809, 12, 13 PRODOTTI FINITI 118 7% 52% 536 5,8% 75,3% 4,5

90, 94, 99 MISCELLANEA 45 3% 55% 434 4,7% 80,0% 9,660, 62, 65 ALLUMINIO 237 14% 68% 424 4,6% 84,5% 1,8

40 41 FOGLIETTI ILLUSTRATIVI 220 13% 81% 397 4 3% 88 8% 1 840, 41 FOGLIETTI ILLUSTRATIVI 220 13% 81% 397 4,3% 88,8% 1,823 WALLET 63 4% 85% 248 2,7% 91,5% 3,980 ROTOLI DI PVC 51 3% 88% 172 1,9% 93,3% 3,402 PRINCIPI ATTIVI 15 1% 88% 168 1,8% 95,1% 11,2

36, 38 BOLLINI PREZZO 120 7% 95% 129 1,4% 96,5% 1,130, 33, 37 ETICHETTE 52 3% 98% 89 1,0% 97,5% 1,7

14 LOSS REPORT 2 0% 98% 63 0,7% 98,1% 31,683 FUSTINI METALLICI 2 0% 99% 46 0,5% 98,6% 23,103 SEMILAVORATO INTERNO 9 1% 99% 42 0,5% 99,1% 4,784 ALVEOLI 2 0% 99% 37 0,4% 99,5% 18,681 POLIETILENE 6 0% 99% 29 0,3% 99,8% 4,887 SACCHETTI ANONIMI 4 0% 100% 12 0 1% 99 9% 2 987 SACCHETTI ANONIMI 4 0% 100% 12 0,1% 99,9% 2,950 CAPSULE 2 0% 100% 3 0,0% 100,0% 1,555 FLACONI 1 0% 100% 1 0,0% 100,0% 1,016 MATERIALE DI SCARTO 1 0% 100% 1 0,0% 100,0% 1,015 RESI A PAVIA 1 0% 100% 1 0,0% 100,0% 1,0

1 742 9 308Totale

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1.742 9.308Totale

FEASIBILITY REPORTExample of inventory analysis

OVERALL FP STOCK TREND @ 2010(Product Family & LVP/MBG)

2 0002.1002.2002.3002.400

1 3001.4001.5001.6001.7001.8001.9002.000

700800900

1.0001.1001.2001.300

palle

ts

100200300400500600

-gen-10 feb-10 mar-10 apr-10 mag-10 giu-10 lug-10 ago-10 set-10 ott-10 nov-10 dic-10

LIVERPOOL 15 15 15 15 15 134 372 114 15 15 15 15

PANDEMIC 436 370 - - - - - - - - - -

gen-10 feb-10 mar-10 apr-10 mag-10 giu-10 lug-10 ago-10 set-10 ott-10 nov-10 dic-10

MARBURG 180 278 217 253 260 16 16 16 16 174 134 170

FLU - - - - - 708 914 176 318 86 86 86

OTHER 267 258 310 437 538 615 454 412 322 349 299 292

MEN 713 1.043 1.153 1.110 1.078 811 528 226 181 706 866 876

Omissis

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FEASIBILITY REPORTDeliverables and outputs

8.000

ROSIA COLD STORAGE YEARLY TRENDOmissis

6.000

7.000

4.000

5.000

allets

3.000

Pa

1.000

2.000

1 2 3 4 5 6 7 8 9 10 11 12

2-8 C STOCK TREND @ 2012 WITH OPTAFLU 2-8 C STOCK TREND @ 2013 WITH OPTAFLU

2-8 C STOCK TREND @ 2014 WITH OPTAFLU 2-8 C STOCK TREND @ 2015 WITH OPTAFLU + MENJUGATE MOVE

CURRENT COLD STORAGE CAPACITY (Bld.20 + Bld.39) COLD STORAGE CAPACITY (Bld.20 + Bld.39 + HBS)

COLD STORAGE CAPACITY (Bld.20 + HBS) COLD STORAGE CAPACITY @ 2015 (Bld.20 +2 HBS)

OmissisOmissis

OmissisOmissis

OmissisOmissis

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FEASIBILITY REPORTExample of flows analysis

PACKAGING TREND in 2010 (pallets)

1.600

1.700

1 200

1.300

1.400

1.500MEN FLU

OTHER MARBURG

PANDEMIC LIVERPOOLOmissisOmissis

900

1.000

1.100

1.200

600

700

800

300

400

500

-

100

200

gen-10 feb-10 mar-10 apr-10 mag-10 giu-10 lug-10 ago-10 set-10 ott-10 nov-10 dic-10

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FROM TO CHART: SITUAZIONE DI PROGETTO (flussi medi giornalieri)MISSIONI PER

Ingr. Sampl. Mag.(HBS)

Mag.(NWH) Weigh. Pre

Weigh.Fraz. Bulk Assem. Manuf. Pack. Pick. Stag. Waste Ship. De/Stac

STA

Ingresso 106 54

Sampling 19

ORIGINE / DESTINAZIONE

Magazzino (HBS) 24 19 45 18 89 59 96 9 37

Magazzino (NWH) 11 94 21 120

Weighing 15 1 18

Pre Weighing 36

Fraz. Bulk 22

Assembling 36 7 30

Manufacturing 7 58 24

Packaging 48 80 16

MIS

SIO

NI D

A

Picking 21 49

Staging 30

Waste 58

Shipping

De/Stacker PT - STA11 11 32 11

Stacker 1P - STA21 19

De/Stacker 1P - STA31 3 55

TOTALE 24 19 368 263 56 50 22 144 97 190 30 30 58 157 38

19


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Each alternative solution must be characterized in terms of:

• Master Plan of the site• Warehouse layout design of logistic equipment (storage and material• Warehouse layout: design of logistic equipment (storage and material

handling means) according to design year requirements• Operative criteria: put‐away rules, warehouse storage mapping, picking

processes (per single order, batch order picking, sorting), handling processesetc.

• Manpower staffing (and relevant running costs)• Manpower staffing (and relevant running costs)• Other running costs (automation maintenance etc.)• Investment costs• Project time schedule / planning of implementation stages

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waste water

36

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cashiers office

Truck Garage

MPoffice

LPGstorage

yard and vehicle wash area

driver's waiting room

battery bay

L

dis abled

l adies gents

8

containers bay

load for Gozo / containers bay

SOLUTION #1SOLUTION #1

Truck

170

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SOLUTION SOLUTION #2#2

22


waste water

64 1

Truck GarageL

water line

45

45

45

45

17

1

1 48

1 291 29

1

7

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7Wrapping

1

3

1

3

1

3

12

NOT OK 68

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FEASIBILITY REPORTEstimate of investment costs

Total costs (€)

Unit costs Full Aut

Qty

Cost Item Unit costs(€/ each) UoM Full Aut.

Sol. Full Aut. Sol.

HBS WAREHOUSE All products

Self supported racks 145€ pp 39.600 5.750.000€ Stacker cranes (double deep & double fork) 330 000€ n° 11 3 630 000€Stacker cranes (double deep & double fork) 330.000€ n 11 3.630.000€

Total 1 9.380.000€ CONVEYOR SYSTEM

Conveyors HBW (in & out) 3.500€ mt 156 550.000€ Turnatable 15.000€ n° 20 300.000€

Total 2 850.000€ MONORAIL SYSTEM (1st level)

Rail & system 1.500€ mt 460 690.000€ Monorail shuttles 35.000€ n° 29 1.015.000€ Lift e conveyors for Production 90.000€ n° 5 450.000€ Mezzanine for maintenance and support 250€ sqm 600 150.000€

Total 3 2.305.000€Total 3 2.305.000€ MONORAIL SYSTEM (ground level)

Rail & system 1.500€ mt 430 645.000€ Monorail shuttles 35.000€ n° 29 1.015.000€ I-point & conveyors 3.500€ mt 15 55.000€ Gravity lanes for replenish. 400€ pp 66 30.000€

1 4 000€Total 3 1.745.000€ SHIPPING AREA

Conveyors @ shipping area (gravity roller) 400€ pp 330 135.000€ Total 5 135.000€

MH & RACKS 14 415 000€

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MH & RACKS 14.415.000€

FEASIBILITY REPORTComparison of alternative solutions

SOLUTION 2 SOLUTION 4 SOLUTION 5SOLUTION 3SOLUTION 1

Product type [type] WATER NO WATER ALL WATER NO WATER ALL ALL

Storage pallet places [#] 3.488 3.290 6.860 3.465 3.164 6.888 6.454

Warehouse saturation [%] 95% 91% 92% 96% 95% 92% 98%

Area utilization factor [pp/sqm] 2,1 1,9 2,6 2,6 1,9 2,6 1,9

Area requirements [sqm] 4.150 4.150 4.850 4.850 4.600 q [ q ]

Area availability [sqm] 700 700 -

Workers / day (peak conditions) [#] 26 20 19

-

21

250

17

Total logistic investment costs [€] 1.611.000 1.548.500 956.500

Total running costs / year [€/y] 462.000 348.000 305.000

2.187.000

291.000

1.200.500

344.000

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vote score vote score vote score vote score vote score

1Overall costs (investment + running) in the mid term (5 years)

25% 9,0 2,3 7,5 1,9 5,0 1,3 7,5 1,9 10,0 2,5

Solution 3 Solution 4 Solution 5Factor description Weight

Solution 1 Solution 2

2 Investment costs impact 10% 8,2 0,8 7,4 0,7 5,0 0,5 6,6 0,7 10,0 1,0

3 Safety & ergonomy 10% 6,0 0,6 9,0 0,9 9,0 0,9 8,0 0,8 7,5 0,8

4 Area savings 10% 5 0 0 5 10 0 1 0 6 8 0 7 10 0 1 0 5 0 0 54 Area savings 10% 5,0 0,5 10,0 1,0 6,8 0,7 10,0 1,0 5,0 0,5

5 Project complexity and lenght 5% 9,0 0,5 8,0 0,4 5,0 0,3 7,0 0,4 10,0 0,5

6 Process & Operations control and accuracy 10% 7,0 0,7 8,0 0,8 10,0 1,0 7,0 0,7 9,0 0,9

7 Flexibility to long term changes 5% 8,5 0,4 5,0 0,3 7,5 0,4 7,0 0,4 9,0 0,5

8 Flexibility to overtime 5% 7,0 0,4 7,0 0,4 10,0 0,5 7,0 0,4 7,0 0,4

9 Flexibility to short peaks of the workload 5% 7,0 0,4 5,0 0,3 6,0 0,3 6,5 0,3 8,0 0,4

10 Sensitivity to failures; availability 5% 10,0 0,5 9,0 0,5 8,0 0,4 7,0 0,4 10,0 0,5

11 Sensitivity to manpower costs dynamics & avaliability 5% 7,0 0,4 5,0 0,3 10,0 0,5 7,0 0,4 8,0 0,4

12 Corporate image benefits 5% 8,0 0,4 7,0 0,4 10,0 0,5 9,0 0,5 7,0 0,4

Total 100% 8,67,7 7,6 7,2 7,6

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FINANCIAL & ECONOMICAL COMPARISON (interest rate = 5%)6.000.000

4.500.000

5.000.000

5.500.000HBW solution becomes more convenient thanVNA trucks solution after about 2,5 years

3 000 000

3.500.000

4.000.000

s (E

uro)

2.000.000

2.500.000

3.000.000

tota

l cos

t

500.000

1.000.000

1.500.000 All racks storage solution is alwaysthe most convenient one in ten yearshorizon

-

2008

2009

2010

2011

2012

2013

2014

2015

2016

2017

2018

SOLUTION 1 SOLUTION 2 SOLUTION 3 SOLUTION 4 SOLUTION 5

27

SOLUTION 1 SOLUTION 2 SOLUTION 3 SOLUTION 4 SOLUTION 5

PROJECT SCHEDULE (GANTT)

28

DYNAMIC SIMULATION DYNAMIC SIMULATION –– samples of 3D animationsamples of 3D animation

29

DYNAMIC SIMULATION DYNAMIC SIMULATION –– samples of 3D animationsamples of 3D animation

30

DYNAMIC SIMULATION DYNAMIC SIMULATION –– sample of time graphsample of time graph

HBS avg Utilization100

80

90

60

70

40

50%

20

30

-

10

0 5 1 5 2 5 3 5 4 5 5 5 6 5 7 5 8 5 9 5 0 5 1 5 2 5 3 5 4 5 5 5 6 5 7 5 8 5 9 5 0 5 1 5 2 5 3 5

31

0,5

1,5

2,5

3,5

4,5

5,5

6,5

7,5

8,5

9,5

10,5

11,5

12,5

13,5

14,5

15,5

16,5

17,5

18,5

19,5

20,5

21,5

22,5

23,5

Hour

SIMCO IS…(for warehouse projects)

Below are some references for warehouse projects handled by SIMCO that, for almostall were followed at all stages from feasibility study to commissioningall, were followed at all stages, from feasibility study to commissioning.

For many of the clients listed SIMCO has also developed consulting activities in otherareas of logistics (demand forecasting, inventory management, distribution networks,t t t i l i ti i d th )

We sorted our main references according to the following criteria:

transport, outsourcing, logistics services and other surveys).

Warehouses with high level of automation (stacker cranes, sorters, LGV etc.);for the most complex of them, Simco made recourse to dynamic simulation

models to refine the project.

Warehouses which, while not including full automated systems for storage,are still very interesting and innovative for their size, for the complexity of the

f f f ( S) fsoftware for the management of warehouse operations (WMS), or for the packaging lines and shipping solutions.

32

SOME REFERENCESComplexWarehouses with Complex

warehouseshigh level ofautomation

IVECO (TORINO)Restructuring world distribution warehouse for spare parts (about 180,000 sqm) Characterized by highRestructuring world distribution warehouse for spare parts (about 180,000 sqm) Characterized by hightechnological standards (two automatic warehouses). The intervention, which has made provision for aradical transformation process, had to take account of a marked heterogeneity of stored products, rangingfrom small parts (mechanical and body) to truck cabins. Training of personnel.

VOLKSWAGEN (VERONA) VOLKSWAGEN (VERONA)Creation of new Italian spare parts warehouse for all Group brands (about 55,000 sqm, with rail link)characterized by high technological standards: two automatic warehouses, one for large metal load units(h = 27 m) and one for totes (h = 14 m). Other warehouses including: valuable products, paints, printed,non-standard, etc. After completion and commissioning period, Simco was assigned new consultancyaimed at consolidating the results and continuous improvement.

NOVARTIS VACCINES (ROSIA -SI)From Master Plan to implematation of the warehousing system (Finished Products, Packaging Materials)of the Plant dedicated to the production of vaccines. The solution includes two automated warehouses forppallets (approximately 15,000 bins) integrated with the Manufacturing Departments and with ShippingArea with monorail shuttles and AGV system. The intervention was carried out in two steps; in bothphases, given the complexity of the project, Simco carried out a dynamic simulation.

THUN (MANTOVA) THUN (MANTOVA)Construction of the new Distribution Center (approximately 35,000 sq. m.) equipped with technologicallyadvanced equipment for the preparation of orders: pick to belt, pick to light, voice picking, high throughputsorter (about 20,000 pieces sorted / hour), automatic forming machines, automated shipping end-of-line,automatic robots for the composition of the shipping pallet. Simco also provided for the drafting of theprocedural manual and training of operating personnel

33

procedural manual and training of operating personnel.

SOME REFERENCESComplexWarehouses with

COCA COLA (NOGARA - VR)Master Plan and Detail Design for the new finished goods warehouse (approx 46 000 sqm) dedicated to

Complexwarehouseshigh level of

automation

Master Plan and Detail Design for the new finished goods warehouse (approx. 46,000 sqm) dedicated tothe main Italian production Plant. The scope of work has also led to the optimization of the bottling end ofthe line / packaging (by dynamic simulation), the rationalization of the layout and of the process of rawmaterials warehouse, evaluation of payback time of automated solutions (consisting in a double deepAS/RS warehouse for the slow-moving products), and planning for implementation of the warehouse.

L’OREAL (SETTIMO TORINESE - TO)Feasibility study, detailed design, assistance for the purchase and construction phases of the newautomated warehouse for the storage of raw materials, semi-finished products and packaging materials.The warehouse (3,700 sqm over 6 long corridors 70 meters) is 12.5 meters high and served in double-

RUMMO (BENEVENTO)Site Master Plan (built in phases) and project for the construction of a new automated warehouse for

deep storage by AS/RS for alletized units. The conveying system integrates the raw materials weighingarea with the plant and with the existing LGV system, on its turn connecting the production departments.

Site Master Plan (built in phases) and project for the construction of a new automated warehouse forfinished goods, adopting self-supported racks (h = 30+ m, with capacity of 40,000 pallet bins) served byfour double deep stacker cranes, direct fed from the palletizers on continuous cycle (3 shifts for 7 days).

MERCK SHARP & DOHME (PV)F thi i t t t f th h ti l t th h b l t di th 30For this important customer of the pharmaceutical sector, there have been several studies over the 30years of life of Simco. The latest deal saw Simco and MSD facing together a complete design process,which has spanned a period of about two years, from an audit on the criticality of the systems of handlingand storage facility, to get the full management by Simco of the detailed project of revamping theautomated warehouse and its "heads". It was previously developed a program, then realized, for the

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expansion of storage and to feed packaging lines from the warehouse by means of automated LGV.


DENSO (CARMAGNOLA - TO)Reali ation of a ne After Sales areho se based on a tomatic stacker cranes for both palleti ed nits


automation

Realization of a new After Sales warehouse based on automatic stacker cranes for both palletized unitsand loose packages, aimed at feeding an automatic picking system. The warehouse was built about 22meters high with self-supported racks.

PONTI (GHEMME - NO)C t ti f di t ib ti h f i d i ti f t ti t kConstruction of a new distribution warehouse for vinegars and preserves, consisting of automatic stackercranes in multi-depth racks (served by and automated "shuttle" on board the AS/RS) connectedautomatically with the preserves production building and in a system of automatic un / loading of trucks forconnection with vinegars production plant. Creation of a traditional picking area, managed with WMS andRF hand-held terminals.

USAG (MONVALLE - VA)Construction of the new general distribution warehouse (loose and packaged finished products, packagingmaterials) and the office building. The warehouse, designed with high-tech solutions, like two automaticwarehouses (one h = 27 m and another one h = 12 m feeding flow racks for picking channels) conveyingwarehouses (one h 27 m and another one h 12 m feeding flow racks for picking channels), conveyingsystems to feed packaging stations, provides for the storage of hand tools (basically small) and cabinetsand carts (basically large).

LEVI STRAUSS ITALIA ( SETTIMO MILANESE - MI)Reorganization of Italian distribution warehouse based on automatic receipt and palletizing of productsReorganization of Italian distribution warehouse, based on automatic receipt and palletizing of productsfrom factories (trucks unloading and conveyance to 3 Cartesian robots for 48 automatic palletizingstations and automated evacuation of pallets there formed) and in the preparation of orders: pallet andboxes flow racks, served by a conveyor system with "decision points"; a "lock & pick" system assists theoperators in the picking zones; automated manifesting line and automated loading of semi-trailers.

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ARTURO SALICE (NOVEDRATE - CO)Two warehouses equipped with automatic stacker cranes: one for semi-finished products (handling ofcontainers quadruples) and one for finished products; for the latter, based on self-supported racks, it wasimplemented a robotized picking station, adopting Cartesian axle equipment.

SIEI (GERENZANO - VA)Site Master Plan, layout and design of the production departments and of an automated warehouse forcomponents, served by stacker cranes (three load units per time) handling standard totes to replenish theassembly lines.

FACET (COLLEGNO - TO)Site Master Plan and implementation of three automated warehouses: raw materials (stacker cranes forpallets of pellets, stored counterslope). For components, semi-finished and packaged finished productswarehouse it all began with a review of the loading unit and the installation of special stacker cranes withi d d t i f f k f h dli t i f diff t i ( t i th th )

G.SACCHI (LISSONE- MI)Implementation of a distribution warehouse to deliver electrical parts and equipment to Customers andAffiliates (18) The warehouse consists of several sections depending on the nature and intensity of

independent pairs of forks for handling containers of different sizes (one twice the other).

Affiliates (18). The warehouse consists of several sections depending on the nature and intensity ofgoods flow: cantilever racks served with a 4-way fork-lift truck for long products, order picking trucks forsmall parts, an automatic system (8 horizontal carousels) again for small parts, racks for palletizedproducts, bulk floor storage for electrical cabinets, automatic self-steering stacker crane for cable reels.

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COMPLASTEX (LUCCA)Implementation of a new automated warehouse equipped with double deep stacker cranes to store


automation

Implementation of a new automated warehouse equipped with double deep stacker cranes, to storepallets of finished canned products; in the head conveying system it was made a special station equippedwith an automatic picking robot.

BIGNAMI (Al BZ) BIGNAMI (Ala - BZ)New distribution warehouse for sporting goods, conceived using an automated warehouse in double deepfor standard cassettes and other traditional systems for palletized products. The packaging activities formixed parcels shall be assisted by an automatic conveyor line, strapping, labeling and buffer for staging.

HAFLIGER (Trezzano S.N. - MI)Implementation of a AS/RS warehouse for coils, served by automatic stacker cranes working in multi deepcounterslope racks, served by shuttles.

BORELLO & MAFFIOTTO (TORINO)New distribution center of technical articles divided into various zones depending on the nature andquantity of goods handled. The storage area was implemented making recourse to high cadence, smallautomatic stacker cranes (miniload).

CF GOMMA (PASSIRANO - BS)Realization of two inter-operational automatic warehouses, for the handling of palletized products used inthe machining process of the rubber-metal.

( )

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DIESEL (MOLVENA -TV)


automation

DIESEL (MOLVENA -TV)Raw materials (pieces of denim fabric and leather) and accessories warehouse, the warehousingtechnique is based on three horizontal carousels and automated lifting platform in the head plants.

GD (BOLOGNA)( )Master Plan and Feasibility Study for the construction of a new automated warehouse with self-supportedracks, for raw and melting components.

CONSERVE ITALIA (BOLOGNA)D i d t i t f lti d t t d h (“ h ttl ”) f fi i h d d

PHARMACEUTICAL DISTRIBUTION ( ITALIA – various locations)50 distribution centers for 35 different customers, characterized by high shipping rates: 10÷50.000 lines per day in a veryconcentrated time window for more and generated by many thousand SKUs

Design and procurement assistance for a multi deep automated warehouse (“shuttles”) for finished goods

concentrated time window, for more, and generated by many thousand SKUs.

Most projects included feasibility study and, subsequently, all activities relating to the installation of highly automatedwarehouses as far as put-to-storage, picking (automatic A frame machines, conveyors with a decision point) and shippingactivities (automated self-closing, sealing and labeling of shipping packages / totes, automatic sorting out to the differentaccumulation bays)accumulation bays).

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BTICINO (OSPEDALETTO LODIGIANO)Implementation of a centralized warehouse for Legrand (Zibido S G - PV) and later construction of the


automation

Implementation of a centralized warehouse for Legrand (Zibido S.G. PV) and later construction of thenew finished goods warehouse for Bticino (Legrand Group), dedicated to palletized goods, products inboxes, long loads (cabinets, carpentry etc.). Issuing of detailed warehouse operating procedures and stafftraining. First warehouse in Italy to adopt and use the WMS software "Catalyst".

COCA COLA CCHBC HELLENIC (EUROPE – various locations) COCA COLA CCHBC HELLENIC (EUROPE – various locations)For this customer Simco was choosed as logistics consultant at European level; in the synthesis wererealized the following projects:

ANNO NAZIONE LOCALITA' TIPO DI PROGETTO2003 ITALIA NOGARA Master plan2003 ITALIA NOGARA Master plan2004 ITALIA NOGARA Warehouse layout optimization2004 ITALIA NOGARA Assistance to the realization of warehouse re‐layout2004 ITALIA GAGLIANICO Warehouse layout optimization2004 ITALIA NOGARA Raw materials warehouse + automated connection systems to Production2005 ITALIA NOGARA Feasibility report for automated warehouse

In 2007, through a strictselection process, Simcohas become an official

f CCHBC f 2005 ITALIA NOGARA Optimization of end‐of‐line buffers vs fork‐lift trucks (dynamic simulation)2005 ITALIA BUCCINASCO Feasibility study to assess sustainability of "Go‐to‐market" project as far as picking is concerned2006 ITALIA HQ Parametric model for design of warehouse layout and handling resources2006 ITALIA HQ Training class about warehousing issues2007 GRECIA SCHIMATARI Master plan2007 BULGARIA KOSTINBROD Maser plan + Warehouse layout optimization

partner of CCHBC forconsultancy aboutwarehousing,distribution and systemimplementations.

2007 BULGARIA KOSTINBROD Maser plan + Warehouse layout optimization2008 BULGARIA KOSTINBROD Mapping of Warehouse processes (flow charts)2008 GRECIA AIGIO Feasibility report for finished products warehouse2008 CROATIA ZAGREB Feasibility report for finished products warehouse2009 CROATIA CROATIA Optimization of distribution network (using advanced simulation tools)2009 ITALIA MARCIANISE Feasibility report for finished products warehouse

Simco since then hasbeen involved in severalinternational logisticsprojects for CCHBC.

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y p p2009 ITALIA MARCIANISE Master plan2010 CROAZIA ZAGREB T&M study for picking activities (making recourse to advanced specialistic software tools)2010 ITALIA CAGLIARI Warehouse layout optimization2011 ITALIA ORICOLA Warehouse layout optimization (on‐going)2012 AUSTRIA EDELSTAL Feasibility report for finished products warehouse


COOP (TUSCANY REGION)Study on the reorganization of several distribution centers (Sesto Fiorentino, Pontedera, Castiglione delLago Perugia) evaluation of the opportunities of development interventions checking the correct


automation

Lago, Perugia), evaluation of the opportunities of development interventions, checking the correctgeographical position.

SUBARU (ALA -TN)Re-layout and expansion of an existing warehouse. Simco first developed the Master Plan of the existingf ilit f i th i t f i ti f ti liti f th h i l ti t th l dfacility, focusing on the improvement of existing functionalities of the warehouse in relation to the plannedextensions and then carried out a feasibility study, especially for the verification of the correct flow ofinternal movement of goods and to verify the correctness of the logistics techniques that Subaru intendedto take, to implement the extension.

FABRIZIO ING.PLINIO (ODERZO - TV)Warehouse of approximately 40,000 square meters, built from "green field", where were concentrated thethree previous warehouses located in the basin of Treviso. The system, which distributes both to abroadbranches and directly to regional customers, has a work organization characterized by "man to goods"approach and assisted by a WMS software customized for withdrawals of small parts from totes and fromapproach and assisted by a WMS software customized for withdrawals of small parts from totes and fromcontinuous shelves, from pallets on racks and bulky products stored on the floor, subject to strongseasonality. Simco has developed the feasibility study, the executive project, construction management,testing of hardware and software, management of the relocation and commissioning.

FISCHER ITALIA (PADOVA) FISCHER ITALIA (PADOVA)Warehouse for semi-finished and finished goods, organized in a first section equipped with traditionalracks for palletized goods - served by great lifting height (11,2 m) reach trucks - and in a second section,dedicated to single boxes of finished products, characterized by an high productivity technique for pickingactivities ("pick & pack" for orders batches), consisting of flow racks and shelves for boxes and crates,

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( ) gserved by a manifesting line for shipping packs,(mechanized end-line of pack closure and labeling.)



SNAM RETE GAS (Codogno - LO)Reorganization of the central warehouse for Materials, in the light of the need to increase efficiency andto dedicate storage areas (in order to achieve synergy of Group) to Italgas. The warehouse is arrangedboth on covered areas and on extensive outdoor areas for bulky materials (pipes, valves, structural, etc.).The study identified new ways for picking sequences, aimed at the rationalization of transport; stepswere also taken to identify a group of materials that, due to their characteristics (cost, lead timeprocurement, strategic, etc..) can be managed directly by passing the central warehouse.p , g , ) g y y p g

MATTEL (Arona - VB)Reorganization of the finished products warehouse, which is divided into two sections respectively for thestorage of stocks and for the preparation of orders. The first area is developed with pallet racking servedby turret trucks so as to obtain the best volumetric efficiency the second zone provides different solutions

FRASCHETTI (CEPRANO FR)

by turret trucks so as to obtain the best volumetric efficiency, the second zone provides different solutionsfor storage / withdrawal in relation to the intensity of the flows, e.g. for fast mover is equipped with flowracks for pallets, with stocks on the upper floors and the picking at floor level. The warehouse is managedby an advanced WMS with RF terminals.

FRASCHETTI (CEPRANO - FR)Construction of a new distribution warehouse of diversified (small, palletized products, products with non-standard size) technical materials. Detailed study to redefine load units, organization of storage areas,activation of WMS with RF communications from/to hand-held and truck terminals and mechanizedconveying lines for incoming and outgoing products

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SELEGIOCHI (BINASCO - MI)


automation

( )Renovation of Casarile warehouse and then project for a new distribution center, organized on palletsracks and flow racks for packages, aimed at optimizing routes in picking activities. Activities are supportedby WMS (RF) and end of line packaging, sealing, labeling and sorting parcels with a high content ofautomation.

DANZAS (GRANDATE - CO)Multiclient warehouse for the storage of bales (palletized) of raw silk, made with compactable racksserved by VNA turret trucks.

REVELLO (VERONA)Distribution warehouse for dental products, articulated in several functional areas as a function both ofprocess type and quantity of inventories, like: area for palletized goods, area with mechanized conveyingline for orders picking, to be prepared according to "pick & pack" technique.

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SIMCO: INTERNATIONAL PROJECTS

Simco has intervened abroad on behalf both of clients based in Italy and abroad,

and this represents an international qualification; some of those specific abroad

projects are briefly listed hereafter:

COCA COLA (CCHBC HELLENIC)After having developed many studies in Italy, CCHBC used Simco for different Warehousing and Networkprojects, namely:

A t i• Austria• Bulgaria (2 projects)• Croazia (3 projects)• Grecia (2 projects)

FIAMM AUTOMOTIVEReorganization of the warehouse in Czech Republic

GENERAL SOFT DRINKSDesign of the new distribution warehouse in Valletta (Malta)

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SIMCO: INTERNATIONAL PROJECTS

INDUSTRIE CARTARIE TRONCHETTI (POLAND)Technical comparison of solutions proposed by a number of Vendors for an automatic warehouse of theTechnical comparison of solutions proposed by a number of Vendors for an automatic warehouse of thePolish production plant, for storage and distribution of the finished products. Design of a newly conceivedreference solution, i.e. an high intensity (approximately 50,000 load unit locations) automatic warehouse(self-supporting racks) equipped with a fully automated and integrated conveying system for transferringthe goods from the production lines to the warehouse (monorail) and from the latter to the area ofshipping suitable for supporting high intensity material handling flows (> 300 load units / h in&out)

STAPLES (EUROPE)Implementation of a training plan to be delivered in English to all European subsidiaries on inventorymanagement with relevance to the operation of the new Oracle ERP.

shipping, suitable for supporting high-intensity material handling flows (> 300 load units / h in&out).

management with relevance to the operation of the new Oracle ERP.

TEMPUR (EUROPE)After carrying out a consultancy for Tempur Italy, Simco was appointed to carry out a study on theEuropean distribution network for its optimization.European distribution network for its optimization.

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SIMCO: LOGISTIC SERVICE PROVIDERS (LPS)

Simco carried out many projects for the outsourcing of distribution and logisticsactivities, by performing the analysis of convenience, preparing and managing they g y g g gtender for the award of service on the basis of a technical specification, where wealso defined the default tariff structure, based on main cost drivers.

Hereafter a list of some of our major Customers for outsourcing projects:

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WARHOUSE_PLANNING.pdf - Simco Consulting

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