3-PL Cold Storage Automation Proposal

Steven Plothow January 29, 2019

NOR-AM

Initial Layout / Design

2

Nor-Am, St. Joseph MO: Initial Data

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3

Nor-Am: Photos of Current Pallets

Pallet w Plastic Wrap on top & no Plastic Pallet w no Plastic Inserts Inserts

Pallet w no Plastic Inserts

Pallet w Plastic Inserts

Pallets w Plastic Inserts Plastic Inserts

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4

Nor-Am: Box Sizes and Usage IBP Case Ready - Box Usage Box Ready 3rd quarter Sales - BI invoices Only

Easy Auto-Pallet Build Candidates - Same Tier Pattern Box Code M N S T

Description #2 GB #5 GB #10/Fshort #10/Fdeep

Box Dimensions (OD)

Length 22.0625 in 20.688 in 22.159 in 21.9375 in

Width 14.3125 in 13.313 in 14.784 in 14.5625 in

Height 9.0625 in 7.625 in 8.193 in 11.125 in

Box Weight Range (lbs) 26 - 27 20 - 23 9 - 26 19 - 41

Conveyable yes yes yes yes TOTALS

Boxs Shipped Number of Percent of SKUs Beef Gr. Beef Pork Total Boxs 5 -56,052 -5.3% 7 -104,812 -9.9% 42 199,309 -92,919 27.7% 26 85,255 -135,931 21.0% 80

64%

Other Box Sizes Box Code B C F L G W A V H K X

Description #3 short #3 deep #5 short #1 GB #5 deep cryo trim cryo cryo trim cryo

Box Dimensions (OD)

Length 18.1875 in 18.1875 in 16.6874 in 21.3125 in 16.6874 in

Width 14.5625 in 14.5625 in 11.5625 in 18.3125 in 11.5625 in

Box Weight Number of Height Range (lbs) Conveyable SKUs 8.625 in 8 - 24 yes 32 11.0575 in 18 - 26 yes 6 12.375 in 15 - 21 yes 16 10.625 in 13 - 26 yes 7 17.6875 in 24 - 38 no -Phasing Out 6 42 - 43 unknown 1 29 - 59 unknown 3 13 - 15 unknown 2 34 - 35 unknown 1 11 - 12 unknown 2 20 - 36 unknown 6 TOTALS

82

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Boxs Shipped Percent of Beef Gr. Beef Pork Total Boxs 74,745 -16,512 8.7% 20,961 -10,256 3.0% 88,708 --8.4% -80,533 -7.6% 1,852 -54,927 5.4% --698 0.1% --3,399 0.3% --3,767 0.4% --5,023 0.5% -8,793 -0.8% --9,432 0.9% 36%

5

Nor-Am: Pallet Ti / Hi Offal 4 Tie 8 Layers

Offal 6 tie 8 or 9 layers

FAB 5 tie 5-6-7-8 layers same all the way up except 2nd to last layer reverse pattern

16"

16"

24"

24"

16"

24"

24" 16"

21"

42"

32.00 768.00 Inches

21"

16"

42"

24.00 64.00 Feet

16"

24"

16"

21"

16" 24"

16"

21"

FTB 5 tie 6 layer same pattern all the way up

54.00 1,134.00 Inches

24"

16"

16"

40"

21.00 94.50 Feet

40.00 960.00 Inches

24" 40"

24.00 80.00 Feet

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30.00 720.00 Inches

24.00 60.00 Feet

6

Nor-Am: Rates Cases per Hour CURRENT Shifts Hours/Shift Days of Storage

Week 1 Week 2 Week 3 Week 4

EXPECTED INBOUND

3 6.7 3

Shifts Hours/Shift Days of Storage

Weekly Total Mon Tues Weds Thurs Fri Sat Days/Wk 134,422 26,884 26,884 26,884 26,884 26,884 5 136,638 27,328 27,328 27,328 27,328 27,328 5 160,000 26,667 26,667 26,667 26,667 26,667 26,667 6 133,021 26,604 26,604 26,604 26,604 26,604 5

CASES PER HOUR Week 1 Week 2 Week 3 Week 4

Mon 1,346 1,368 1,335 1,332

Tues Weds Thurs 1,346 1,346 1,346 1,368 1,368 1,368 1,335 1,335 1,335 1,332 1,332 1,332

CASES PER MINUTE Week 1 Week 2 Week 3 Week 4

Mon Tues Weds Thurs 22.4 22.4 22.4 22.4 22.8 22.8 22.8 22.8 22.2 22.2 22.2 22.2 22.2 22.2 22.2 22.2

STORAGE Week 1 Week 2 Week 3 Week 4

Mon Tues Weds Thurs Fri Sat Days/Wk 80,653 80,653 80,653 80,653 80,653 0 5 81,983 81,983 81,983 81,983 81,983 0 5 80,000 80,000 80,000 80,000 80,000 80,000 6 79,813 79,813 79,813 79,813 79,813 0 5

Week 1 Week 2 Week 3 Week 4

2 10.0 3 Weekly Total 175,000 175,000 175,000 175,000

26.47% 15.18% 7.93% 16.31% 19.96% 14.15% Mon Tues Weds Thurs Fri Sat Days/Wk 29,167 29,167 29,167 29,167 29,167 29,167 6 29,167 29,167 29,167 29,167 29,167 29,167 6 29,167 29,167 29,167 29,167 29,167 29,167 6 29,167 29,167 29,167 29,167 29,167 29,167 6

Fri Sat Days/Wk 1,346 5 1,368 5 1,335 1,335 6 1,332 5

CASES PER HOUR Week 1 Week 2 Week 3 Week 4

Mon Tues Weds Thurs 1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458

Fri 1,458 1,458 1,458 1,458

Sat Days/Wk 1,458 6 1,458 6 1,458 6 1,458 6

Fri 22.4 22.8 22.2 22.2

CASES PER MINUTE Week 1 Week 2 Week 3 Week 4

Mon Tues Weds Thurs 24.3 24.3 24.3 24.3 24.3 24.3 24.3 24.3 24.3 24.3 24.3 24.3 24.3 24.3 24.3 24.3

Fri 24.3 24.3 24.3 24.3

Sat Days/Wk 24.3 6 24.3 6 24.3 6 24.3 6

STORAGE Week 1 Week 2 Week 3 Week 4

Mon 87,500 87,500 87,500 87,500

Fri 87,500 87,500 87,500 87,500

Sat Days/Wk 87,500 6 87,500 6 87,500 6 87,500 6

Sat

Days/Wk 5 5 22.2 6 5

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Tues Weds 87,500 87,500 87,500 87,500 87,500 87,500 87,500 87,500

Thurs 87,500 87,500 87,500 87,500

7

Nor-Am: Rates Cases per Hour EXPECTED OUTBOUND Shifts Hours/Shift Days of Storage

Week 1 Week 2 Week 3 Week 4

3 8.0 3 Weekly Total 175,000 175,000 175,000 175,000

26.47% 15.18% 7.93% 16.31% 19.96% 14.15% Mon Tues Weds Thurs Fri Sat Days/Wk 46,326 26,570 13,872 28,542 34,932 24,757 6 46,326 26,570 13,872 28,542 34,932 24,757 6 46,326 26,570 13,872 28,542 34,932 24,757 6 46,326 26,570 13,872 28,542 34,932 24,757 6

CASES PER HOUR Week 1 Week 2 Week 3 Week 4

Mon Tues Weds Thurs 1,930 1,107 578 1,189 1,930 1,107 578 1,189 1,930 1,107 578 1,189 1,930 1,107 578 1,189

Fri 1,456 1,456 1,456 1,456

Sat Days/Wk 1,032 6 1,032 6 1,032 6 1,032 6

CASES PER MINUTE Week 1 Week 2 Week 3 Week 4

Mon Tues Weds Thurs 32.2 18.5 9.6 19.8 32.2 18.5 9.6 19.8 32.2 18.5 9.6 19.8 32.2 18.5 9.6 19.8

Fri 24.3 24.3 24.3 24.3

Sat Days/Wk 17.2 6 17.2 6 17.2 6 17.2 6

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8-9

9-10

10-11

11-12 619

8-9

9-10

10-11

11-12

1,458

1,458

1,458

1,458

1,458

1,458

1,458

1,458

1,238

1,238

1,238

1,238

1,238

1,238

1,238

1,238

1,238

1,238

4-5

5-6

6-7

7-8

8-9

9-10

10-11

11-12

5-6 4-5 3-4 2-3 1-2 619

619

619

0-1

1-2

2-3

3-4

12-1 619

11-12 10-11 9-10 8-9 7-8 6-7 5-6 4-5 3-4 2-3 1-2 12-1 11-12 10-11 9-10 8-9 7-8 6-7 5-6 4-5 3-4 2-3 1-2 0-1

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

714 714 714 714

10-11

Cases / Hour Cases / Hour

1,427

9-10

1,427

8-9

1,458

1,427

7-8

1,458

1,427

6-7

1,458

1,427

5-6

1,458

1,427

4-5

1,458

1,427

3-4

1,458

1,427

2-3

1,458

1,427

1-2

1,458

1,427

6-7

1,458 1,238

1,458

1,427

0-1

5-6

6-7

7-8

8-9

9-10

10-11

11-12 1-2

2-3

3-4 0-1

1-2

2-3

3-4

4-5

5-6

6-7

7-8

8-9

9-10

10-11

11-12

12-1

1-2

2-3

3-4

4-5

5-6

6-7

7-8

8-9

9-10

10-11

11-12

0-1

1-2

2-3

3-4

4-5

5-6

6-7

7-8

8-9

9-10

10-11

11-12

12-1

1-2

2-3

3-4

4-5

5-6

6-7

7-8

8-9

9-10

10-11

11-12

0-1

12-1

1-2

2-3

3-4

4-5

5-6

6-7 4-5

7-8

619

694

1,458 1,238

7-8

1,458

1,458 694

347 619

1,458 694

1,458 1,458

1,458 694

347 619

1,458 694

1,458 1,458

1,458 694

347

1,458 694

1,458 1,458

1,458 694

347

1,458 694 1,458 1,238

1,458

1,427

714 714 714

Outbound

1,458

1,458 694 1,458 1,238

1,458

1,427

0

1,458

1,458 1,238

1,458

1,427

0

694

1,458

1,458873 1,458873 1,458873 1,458873 1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458 873

1,458 873 873 873

1,458

1,427

250 0

1,458

1,747 1,747 1,747 1,747 1,747 1,747 1,747 1,747 1,747 1,747 1,747 1,747 1,747 1,747

1,458 1,458

1,458

1,458

1,458

1,427

250

694

1,458

1,750

1,747

1,000

1,238

1,750

1,458

500 250

714

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1,500

1,458

2,250 2,000

1,747

2,250

2,000

1,458

664 664 664

664 664 664

2,250

1,458

2,500

347

0

347

0

347

250 0

Inbound Outbound

500

347

250

664

250

664

1,750

2,500

694

Cases / Hour 1,329 1,329 1,329 1,329 1,329 1,329 1,329 1,329 1,329 1,329 1,329 1,329 1,329 1,329 1,329 1,329

Cases / Hour 1,158 1,158 1,158 1,158

2,000

2,500

1,458

1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458

1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458 1,458

Cases / Hour

2,316 2,316 2,316 2,316 2,316 2,316 2,316 2,316 1,458 1,458 1,458 1,458 1,458 1,458 1,458

500

Hours of the Day Hours of the Day

Hours of the Day

Inbound

Outbound Inbound

2,316 2,316 2,316 2,316 2,316 2,316 2,316

1,158 1,158

750 500

500

1,158

750

750

1,000

1,000

Saturday: Cases / Hour (Inbound/Outbound) Friday: Cases / Hour (Inbound/Outbound)

Thursday: Cases / Hour (Inbound/Outbound)

1,250 1,250

1,250

750

1,158 500

Outbound Inbound Outbound Inbound

1,250 1,250 1,250

Hours of the Day Hours of the Day Hours of the Day

1,000 1,000 1,000

Outbound Inbound

1,500 1,500

750 750

1,500

694

1,750

694

2,000 1,750

1,458

2,250 2,000

1,458

2,250

694

2,250

1,458

2,500

1,750

Wednesday: Cases / Hour (Inbound/Outbound) Tuesday: Cases / Hour (Inbound/Outbound)

Monday: Cases / Hour (Inbound/Outbound)

1,458

2,500 2,316

2,500

2,000

1,500

1,500

Cases / Hour

8

Nor-Am: Rates Cases per Hour (Each Day)

9

Nor-Am: Rates Cases per Hour (for the Week) Week Inbound/Outbound - Cases / Hour 35,000

35,000

33,575

32,500

30,523

29,167

30,000

27,500

27,500

25,000

25,000

22,500

22,500

20,000

20,000

17,500

17,500

15,000

15,000

12,500

12,500

10,000

10,000

9,350

7,500

7,500

5,000

5,000

2,500 0

2,316 1,458

1,458

1,458

1,458

1,747

1,458

2,500

1,329

694

1,427

1,458

1,238

0

Mon -0-1 Mon -3-4 Mon -6-7 Mon -9-10 Mon -12-1 Mon -3-4 Mon -6-7 Mon -9-10 Tues-0-1 Tues-3-4 Tues-6-7 Tues-9-10 Tues-12-1 Tues-3-4 Tues-6-7 Tues-9-10 Wed-0-1 Wed-3-4 Wed-6-7 Wed-9-10 Wed-12-1 Wed-3-4 Wed-6-7 Wed-9-10 Thurs-0-1 Thurs-3-4 Thurs-6-7 Thurs-9-10 Thurs-12-1 Thurs-3-4 Thurs-6-7 Thurs-9-10 Fri-0-1 Fri-3-4 Fri-6-7 Fri-9-10 Fri-12-1 Fri-3-4 Fri-6-7 Fri-9-10 Sat-0-1 Sat-3-4 Sat-6-7 Sat-9-10 Sat-12-1 Sat-3-4 Sat-6-7 Sat-9-10

Cases / Hour

30,000

32,500

Inbound

Outbound

Running Inventory

Max Locations

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10

Nor-Am, St. Joseph MO: Initial Design

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11

Nor-Am: Aerial View of the Building

Building to install new equipment

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12

Nor-Am: Plan View of the Building

Building to install new equipment

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13

Nor-Am: Flow Chart with Rates & Tray Handling Meat Processing / Receiving

24 Cases/Min

6 Cases/Min

6 Cases/Min

6 Cases/Min

Tray Buffer

6 Cases/Min

6 trays/Min

6 trays/Min

6 trays/Min

6 trays/Min

Place Case on Tray

Place Case on Tray

Place Case on Tray

Place Case on Tray

Truck Docks

24 Cases/ Min

P&D #1

P&D #2

P&D #3

P&D #4

Sortation/Diverts 5 Cases/Min

5 Cases/Min 5 Cases/Min

5 Cases/Min

5 Cases/Min

5 Cases/Min

Case-Product Buffer Total Locations 87,500 for 3 days inventory or 33,575 locations for 1 day inventory 6.5 Cases/Min

͞Jack-Pot͟ No Reads

Correct ͞Jack-Pot͟ Issues

Max Max Rate Rate of of 39 Cases/ 39 Cases/ Min Min

6.5 Cases/ Min

6.5 Cases/ Min

Sortation/Diverts

39 Trays/Min

Full Pallet Buffer Static Rack

Tray Wash

1.3 Pallets/Min 78 Pallets/Hr

Palletizer

39 Cases/Min

P&D #6

39 Trays/Min

Tray Stacker

͞Jack-Pot͟ No Reads

20% 0.26 Pallets/Min 15.6 Pallets/Hr P&D #5

6.5 Cases/ Min

6.5 Cases/Min 6.5 Cases/Min

80% 1.04 Pallets/Min 62.4 Pallets/Hr

Remove Carton from Tray

39 Cases/Min

30 Cases/pallet 39/30=1.3 pallets/ min

2-891i Palletizers

1.3 Pallets/Min 78 Pallets/Hr

Pallet Wrapper

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14

Nor-Am: Why a Shuttle ASRS instead of a Crane-Type AS/RS A Crane-type ASRS e.g. Mini-Load Dual Shuttle System • Rates for this type of ASRS is 130-135 Loads per hour for a dual cycle or 2.1 loads per minute.

A Dual Cycle Pick up loads at P&D

Deliver loads to Rack

Pick Loads in Rack

Deliver Loads to P&D

• Rates for Single Cycles are about 160-180 loads per hour. Single cycles are about 3 cases per minute for the Mini-Crane ASRS. A Single Cycle Pick up loads at P&D

Pick Loads in Rack Deliver Loads to P&D

• With Max System rates of 39 cases per minute outboung.Rates for Single Cycles are about 160-180 loads per hour. Single cycles are about 3 cases per minute for the Mini-Crane ASRS. Honeywell Confidential - © 2019 by Honeywell International Inc. All rights reserved.

15

Nor-Am: Block Diagram for Design #1

Inbound Sorter

Tray Dispenser

Inbound at Floor Level Honeywell Confidential - © 2019 by Honeywell International Inc. All rights reserved.

16

Nor-Am: Block Diagram for Design #2 Outbound Sorter To Tray Dispenser Static Pallet Rack Buffer

Tray Stacker and Wash

Queue for Cases

Bander or Wrap

Outbound Dock Doors

Palletizers

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17

Nor-Am, St. Joseph MO: Initial Sketchup Design /w Tray Handling

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18

Nor-Am: Sketchup Plan View /w Tray Handling

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19

Nor-Am: Sketchup Isometric View /w Tray Handling

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20

Nor-Am: Sketchup Inbound to Tray Dispensers Isometric View

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21

Nor-Am: Sketchup-Tray Dispensers Isometric View /w Tray Handling

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22

Nor-Am: Sketchup-Path to Shuttle ASRS /w Tray Handling

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23

Nor-Am: Sketchup-Inbound/Outbound for Shuttle ASRS /w Tray Handling

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24

Nor-Am: Sketchup-Outbound for Tray Removal /w Tray Handling

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25

Nor-Am: Sketchup-Tray Removal, Tray Wash, & Carton Takeaway /w Tray Handling

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26

Nor-Am: Sketchup-Carton Queuing for Palletizers /w Tray Handling

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27

Nor-Am: Sketchup-Palletizing and Stretch Wrap /w Tray Handling

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28

Nor-Am: Sketchup-Robotic Pallet Take-Away /w Tray Handling

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29

Nor-Am: Sketchup-Robotic Pallet Take-Away /w Tray Handling

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30

Nor-Am: Sketchup-Robotic Stands in Static Rack & Dock Area /w Tray Handling

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31

Nor-Am, St. Joseph MO: Initial Sketchup Design w/o Tray Handling

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32

Nor-Am: Flow Chart with Rates w/o Tray Handling Meat Processing / Receiving

Truck Docks

24 Cases/ Min

P&D #1

P&D #2

P&D #3

P&D #4

Sortation/diverts 5 Cases/Min 5 Cases/Min

5 Cases/Min

5 Cases/Min 5 Cases/Min

5 Cases/Min

Case-Product Buffer Total Locations 87,500 for 3 days inventory or 33,575 locations for 1 day inventory 6.5 Cases/Min

P&D #5

6.5 Cases/ Min

6.5 Cases/Min

6.5 Cases/ Min Max Rate of 39 Cases/ Min

Full Pallet Buffer Static Rack

Sortation/diverts

͞Jack-Pot͟ No Reads

20% 0.26 Pallets/Min 15.6 Pallets/Hr

6.5 Cases/ Min

6.5 Cases/Min

Correct ͞Jack-Pot͟ Issues

͞Jack-Pot͟ No Reads

80% 1.04 Pallets/Min 62.4 Pallets/Hr

1.3 Pallets/Min 78 Pallets/Hr

Palletizer

39 Cases/Min

30 Cases/pallet 39/30=1.3 pallets/ min

2-891i Palletizers

1.3 Pallets/Min 78 Pallets/Hr

Pallet Wrapper

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P&D #6