Block&Flow&Analysis&
With&the&imminent&approval&of&the&additional&space&allocated&in&the&pour–room&MER&there&is&an&
increased&sense&of&urgency&in&resolving&the&new&potential&stresses&that&will&be&placed&on&the&warehouse&
and&its&various&processes.&&Looking&at&an&analysis&our&current&personnel,&product&mix,&forklift&allocation,&
floor&space,&and&total&throughput&will&help&provide&a&comprehensive&solution&to&the&challenges&facing&
the&warehouse&in&the&coming&transition.&
Below&you&will&find&analysis&to&show&that&in&order&to&create&a&functional&operation&we&will&need&a&total&of&
9&forklifts,&9&operators,&and&the&possibility&of&a&shift&supervisor&to&provide&the&requisite&oversight&of&the&
process.&
Backstack’
Now&that&space&for&pouring&is&presumably&resolved,&the&next&challenge&will&be&getting&the&foam&out&in&a&
timely&manner.&&Based&on&the&expectation&of&a&3700&blocks&per&week&consumption/pouring&average&we&
expect&to&pour&740&blocks&per&day.&&These&blocks&need&to&be&removed&from&the&curing&area&to&various&
staging&and&warehouse&locations&in&trips&of&2&or&3&blocks&per&trip.&&Taking&a&snap&shot&of&our&inventory&we&
see&that&about&20%&of&our&blocks&require&a&two&block&carry.&
#&of&Blocks&Carried&
Average&Transit&Time&
Average&loads&carried&&&&&
per&night&
Total&Minutes&of&Block&
Transportation&
2&
2.51&min&
74&
186&min&
3&
3.77&min&
197.3&
592&min&
The&total&is&about&13&hours&of&dedicated&block&transit&time&on&an&average&night.&
In&addition&to&this&will&be&the&time&to&sort&and&stack&the&sea&of&blocks&left&to&cure&in&the&hot&chop&room.&&
At&least&one&operator&will&be&needed&to&sort,&organize,&and&stack&blocks&in&preparation&to&be&back–
stacked.&
In&summary,&1.5&operators&will&be&needed&for&transit&and&1+&operators&will&be&needed&for&organizing&and&
stacking,&a&total&of&3&operators&with&3&lifts&
Scanning’Flagged’Buns’
This&process&is&unique&to&the&Riverside&process&because&of&hot&chop.&&It&involves&taking&one&out&of&every&5&
blocks,&removing&the&flag&physically&placed&in&the&block,&placing&the&block&in&the&cold&laser&scanner,&
organizing&and&stacking&scanned&buns&and&returning&them&to&a&warehouse&location.&&&
On&an&average&night&there&will&be&148&of&these&buns&staged&next&to&the&bun&scanner.&&Time&studies&on&
grabbing&and&feeding&the&blocks&into&the&scanner&show&that&the&average&block&to&process&with&a&single&
operator&takes&about&3.37&minutes&per&block.&
&
&
Based&on&these&studies&148&blocks&scanned&at&3.37&minutes&per&block&results&in&8.31&hours&of&continuous&
block&movement.&&This&process&will&require&1&operator&and&1&forklift.&
Crush’Blocks’
First&let’s&look&at&our&current&crushing&efficiency&tracked&over&the&last&3&months.&&&
6&
Average’Blocks’Crushed’per’Night’
12&
10&
9&
&&
Measurement&#&(Scanning&Process)&
2&
4&
6&
average‘
1&
Obtain&and&Stage&Blocks&(carry&3)—average&
travel&distance—>&(216&ft)—3&Blocks&
1.14&
3.38&
3.3&
2.63‘
2&
Measure&/&Remove&Flags&(per&3&Blocks)&
1.76&
1.93&
1.98&
1.89‘
3&
Place&Blocks&on&Conveyor,&after&3rd&Block&is&
placed&go&to&end&of&conveyor&and&stack&3&blocks.&
1.6&
1.7&
1.6&
1.60‘
4&
Take&Blocks&to&WH&Locations&
3.57&
4.76&
3.70&
4.00‘
&
&&
&
&
&
&
&
&
3.37&
Hours&
Worked&
5&
Time&per&block&