In your group, you are required to produce a distribution centre design to accommodate the detailed scenario.

Scenario

• Sector – Retail
• Operating hours – 2 shifts, 8 hours a day Mon-Fri, 6.30am – 11.30pm
• Volumes – reasonably constant, seasonal 20% peaks in Apr/May and Oct/Nov.
• Growth – 5% per annum.
• Design timeline – 5 years
• Products – 5,000 SKU’s
o 60% Palletized.
• Each SKU has 1 pick location and an average 5 replenishment/storage locations.
• Each pallet is ‘Standard US’ (40” x 48”) built 48 inches high.
o 30% Shelving. Each SKU has an average dimension of 12”x18”x10” and an average quantity holding of 20 items, no replenishment locations.
o 10% Bulk. Each SKU has an average dimension of 5’x6’x8’ and an average quantity of 4 items, no replenishment locations.
• Storage:
o Racking - 5 levels high, 96" bay width (2 pallets), and depth is 42" with 8" gap between back-to-back racking
o Shelving - 10 foot high, 48" deep, configurable shelves.
• Office Requirements – 20,000 sq/ft (Management, HR, Clerical, etc.)
• Ceilings – 40 foot clear
• Aisle widths – 10 foot
• Walkway widths - 4 foot
• Mechanical Handling Equipment:
o Pump Jacks – 10
o Single pallet Walkies – 20
o Double pallet Walkies 10
o Forklift Trucks - 15
• Pallet putaway productivity – 15 pallets/hour
• Picking productivity – 30 picks/hour
• Inbound Receipts – 100 floor-loaded containers per week, productivity 15 man-hours per container.
• Outbound Shipping – 200 store shipments per week, productivity 10 man-hours per shipment.
• Trailer Parking in Yard – 100 trailers

• Other space considerations:

o Battery Changing
o Maintenance
o Returns/Inspection area
o Security
o Janitorial
o Staff Changing Rooms
o Washrooms
o Cafeteria
o IT
o Forklift and MHE parking
o Cardboard compactor
o Plastic wrap compactor
o Trash