📋 Executive Summary
Key findings and conclusions from the capacity study across all VTC sites.
Owned fleet is insufficient to meet current operational demand
Analysis of operational logs confirms that all 6 rented units are structurally required. No owned equipment can be redeployed to external warehouses without disrupting active operations. Rented units are not a discretionary cost — they are an operational necessity driven by site isolation, equipment restrictions, and measured utilization levels.
| Site | Owned | Rented | Shifts | Power Type | Avg Utilization | Shareable? | Rental Justification | Verdict |
|---|---|---|---|---|---|---|---|---|
| Plant 1 — Hazardous Waste | 1 Sit-Down (gas) | 0 | 2 | Gas | ~69% | No | Dedicated + regulatory area | No rental needed |
| Plant 1 — Steel Yard / Patio | 1 Sit-Down (gas) | 0 | 2 | Gas | ~89% | No | Heavy outdoor loads, continuous use | No rental needed |
| Plant 1 — Receiving / Warehouse | 1 Sit-Down (elec) | 0 | 2 | ⚡ Electric | ~51% | No — 8hr charge needed | No spare time to relocate | No rental needed |
| Plant 1 — Reach Truck (Warehouse) | 1 Reach (elec) | 0 | 2 | ⚡ Electric | ~83% | No — 8hr charge needed | Rack operations, no downtime available | No rental needed |
| Plant 2 — Materials / MPU | 4 Sit-Down + 2 Reach (elec) | 2 | 2 | ⚡ All Electric | 57–83% | No — 8hr charge + 2 shifts | No spare unit available for relocation | Rental justified |
| Minerales Yard | 2 Sit-Down (gas) | 1 | 2 | Gas | 94.2% | No — separate location | Capacity saturated — no backup | Rental critical |
| Industrias Warehouse | 2 Sit-Down + 1 Reach | 1 Reach | 2 | Mixed | 87–93% | No — low dock, 2 shifts | 93% utilization + dock restriction | Rental justified |
| Industrias 3 (Annex) | 0 | 1 Reach | 1–2 | — | Continuous | No — dock restriction | No owned equipment, dock too low | Rental justified |
| Llantera (Remote Warehouse) | 0 | 1 Sit-Down | 1 | — | ~25% | No — geographically remote | Transfer cost > monthly rental | Rental justified (geographic) |
Owned Units
19
Sit-down lifts + reach trucks
Rented Units
6
All operationally active
Sites Covered
6
P1, P2, Minerales, Ind, Ind3, Llantera
Rentals Justified
6/6
100% have technical justification
🗺️ Current Fleet Distribution
VSM showing the current forklift fleet across all 6 VTC sites — 19 owned (blue) vs. 6 rented (amber).
Figure 1 — Current State VSM: Forklift Fleet Distribution across 6 sites (25 units total: 19 Owned, 6 Rented)
🏭
Plant 1 (VTCWP1)
7 Sit-Down1 Reach
8 owned · 0 rented
🏭
Plant 2 (VTCWP2)
4 Sit-Down+2 Rent2 Reach
6 owned · 2 rented
⛏️
Minerales Yard
2 Sit-Down+1 Rent
2 owned · 1 rented
🏢
Industrias Warehouse
2 Sit-Down1 Reach+1 Reach Rent
3 owned · 1 rented
🏪
Industrias 3 (Annex)
1 Reach Rent
0 owned · 1 rented
🛞
Llantera (Remote)
1 Sit-Down Rent
0 owned · 1 rented
Rented Equipment Inventory — 6 Units
P2 CONTRACT (4 Units)
🔴 Sit-Down Lift — MPU Shipping → Plant 2
🔴 Sit-Down Lift — Hazardous Waste → Plant 2
🔴 Sit-Down Lift — Minerales Yard
🔴 Reach Truck — Industrias Warehouse
P1 CONTRACT (2 Units)
🟡 Sit-Down Lift (7,000 lbs) — Llantera
🟡 Reach Truck (4,500 lbs) — Industrias 3 (Annex)
📊 Capacity Study — Utilization Analysis
Measured utilization per site and equipment. ⚡ Electric units require 8-hour charging windows, eliminating any possibility of redeployment across shifts.
🏭 Plant 1 — Total Warehouse & Yard Requirement
Data captured Aug 14, 2026 · Shift 1 only · Actual demand = 2× (plant runs 2 shifts). Electric units require 8-hr overnight charge — no cross-shift or cross-site redeployment possible.
~69%
Haz. Waste #8507
Gas
Gas
~89%
Patio/Steel #0587
Gas
Gas
~51%
Receiving #79563
⚡ Elec
⚡ Elec
~53%
Steel/Acero #9583
Gas
Gas
~83%
Reach Truck (HP)
⚡ Elec
⚡ Elec
| Equipment | Area | Power | Active Hrs (Shift 1) | Projected 2-Shift | Available/Day | Utilization | Available for Relocation? |
|---|---|---|---|---|---|---|---|
| MTC #8507 | Hazardous Waste | Gas | ~6.2 hrs | ~12.4 hrs | 18 hrs | ~69% | No — regulatory area |
| MTC #0587 | Patio / Steel Yard | Gas | ~8.0 hrs | ~16.0 hrs | 18 hrs | ~89% | No — saturated |
| MTC #79563 | Receiving / Warehouse | ⚡ | ~4.6 hrs | ~9.2 hrs | 10 hrs* | ~51% | No — 8hr charge gap |
| MTC #9583 | Steel / Acero / Patio | Gas | ~5.3 hrs | ~10.6 hrs | 20 hrs | ~53% | No — dedicated outdoor loads |
| Reach (Hombre Parado) | Warehouse / Rack | ⚡ | ~7.5 hrs | ~15 hrs | 10 hrs* | ~83% | No — 8hr charge + fully loaded |
| P1 Conclusion: All equipment is fully committed to current operations | 0 hrs spare | ⚠ No units available for redeployment | |||||
* Electric units: 10-hr effective window per shift after 8-hr mandatory overnight charge. Metal Fab and Production Building forklifts not shown — dedicated, non-shareable operations.
🏭 Plant 2 — Capacity vs. Requirement
Data captured Aug 18, 2026 · Shift 1 · All units electric — 8-hr charging window eliminates cross-site redeployment. Plant operates 2 shifts.
~83%
MTC #60169
⚡
⚡
~57%
MTC #60168
⚡
⚡
~68%
MTC #60167
⚡
⚡
>60%
MTC #419 Reach
⚡
⚡
| Equipment | Area / Role | Power | Shift 1 Active | Utilization | Available for Relocation? | Reason |
|---|---|---|---|---|---|---|
| MTC #60169 | Materials / MPU / Yard | ⚡ | 7:47 hrs | ~83% | No | Fully loaded in S1; S2 mirrors demand |
| MTC #60168 | Receiving / Tanques | ⚡ | 5:10 hrs | ~57% | No | 8-hr charge + S2 demand fills remaining capacity |
| MTC #60167 | Receiving / Scrap / Patio | ⚡ | 6:10 hrs | ~68% | No | 8-hr charge + S2 doubles requirement |
| MTC #419 (Reach) | Interior Warehouse / Rack | ⚡ | >5:30 hrs | >60% | No | Reach-specific ops + 8-hr charge |
| Rental — MPU Shipping | Outbound Shipping | — | Full shift | ~90%+ | No | Critical outbound — cannot share |
| Rental — Haz. Waste P2 | Hazardous Waste | — | Full shift | Dedicated | No | Regulatory requirement (PROFEPA) |
| P2 Conclusion: 8-hr electric charging + 2-shift operation = zero spare capacity | ⚠ No units can be redeployed to external warehouses | |||||
⛏️ Minerales Yard — Capacity vs. Requirement
Data from Aug 12–13, 2026 · 2 full days · 3 units · 2 operating shifts. 81 movements logged.
94.2%
Overall Fleet Utilization
50:49 / 54:00 hrs available
50:49 / 54:00 hrs available
81
Movements Logged
2-day sample
2-day sample
3:11
Spare Hrs Between All 3 Units
Near-zero backup capacity
Near-zero backup capacity
| Metric | Value | Assessment |
|---|---|---|
| Owned units at Minerales | 2 Sit-Down (gas) | Operating at 90%+ utilization combined |
| Rented unit | 1 Sit-Down (gas) | Operating at 90%+ utilization |
| Total available hours (3 units, 2 days) | 54:00 hrs | — |
| Total hours used | 50:49 hrs | 94.2% — critically loaded |
| Spare capacity (buffer) | 3:11 hrs across all 3 units | No viable backup |
| Failure risk without rental | High | Single-unit failure would halt yard operations |
| Conclusion: A 4th unit is required for operational safety | Purchase recommended — eliminate rental | |
Minerales Overall Fleet Utilization — 3 units, 2 days94.2%
🏢 Industrias Warehouse — Capacity vs. Requirement
Data from Aug 14, 2026 · 4 equipment · 2 full shifts (7:00 AM – 1:30 AM next day). Dock restriction permanently traps the rented reach truck inside.
~87%
MTC #07 (Sit-Down)
T1 + T2
T1 + T2
~78%
MTC #18515 (Sit-Down)
T1 + T2
T1 + T2
93%
HP-277 Reach (RENTED)
18.3 hrs active / 18.5 available
18.3 hrs active / 18.5 available
~91%
HP-5251 Reach (Owned)
T1 + T2
T1 + T2
| Equipment | Type | Active Hours (T1+T2) | Available Hours | Utilization | Dock Accessible? | Verdict |
|---|---|---|---|---|---|---|
| MTC #07 | Sit-Down (owned) | ~12 hrs | 18.5 hrs | ~87% | Yes | Fully committed to internal ops |
| MTC #18515 | Sit-Down (owned) | ~7.5 hrs | 18.5 hrs | ~78% | Yes | Fully committed; interplant loads included |
| HP-277 (Reach) | RENTED | 14.5 hrs | 18.5 hrs | 93% | No — dock too low | Cannot exit — permanently assigned inside |
| HP-5251 (Reach) | Reach (owned) | ~15 hrs | 18.5 hrs | ~91% | Yes | Fully committed T1+T2 rack operations |
| Conclusion: All 4 units fully loaded. Rented reach runs 93% — highest utilization in the fleet. | ⚠ Purchase HP-277 replacement — keep it inside | |||||
Utilization Summary — All Sites
Industrias — HP-277 Rented Reach (T1+T2 combined)93%
Minerales — Overall Fleet (3 units, 2 days)94.2%
Plant 1 — Patio/Steel MTC #0587 (projected 2 shifts)~89%
Plant 1 — Reach Truck (projected 2 shifts)~83%
Industrias — HP-5251 Owned Reach (T1+T2)~91%
Plant 2 — MTC #60169 (projected 2 shifts)~83%
Industrias — MTC #07 (T1+T2)~87%
Plant 2 — MTC #60167 (projected 2 shifts)~68%
Plant 2 — MTC #60168 (projected 2 shifts)~57%
Llantera — Remote Warehouse (3–4 moves/week)~25%
📍 Site Detail — Operational Logs
Select a site to view individual equipment movement records.
Equipment Logged
5
8507, 0587, 9583, Reach HP, 79563
Total Moves (Shift 1)
71
Aug 14, 2026
Gas Units
3
8507, 0587, 9583
Electric Units
2
79563 + Reach (8-hr charge)
Rented
0
Plant 1 self-sufficient
MTC #8507Hazardous Waste Area · Aug 14 · Shift 1Gas~69% Utilization
| # | Route | Product | Weight | Start | End | Duration |
|---|---|---|---|---|---|---|
| 1 | Yard / Transfer Aisle | Pallets | 400 kg | 7:00 | 7:55 | 55 min |
| 2 | Vibration Study Support | — | — | 8:10 | 8:20 | 10 min |
| 3 | Loaned to Shipping | Material | ? | 8:25 | 8:45 | 20 min |
| 4 | Load Riqueza Truck | Pallets (~4 tons) | 4,000 kg | 8:25 | 10:40 | 2:15 hrs |
| 5 | Collect Transfer Pallets | 11 pallets | 200 kg | 10:55 | 11:15 | 20 min |
| 6 | Loaned to Warehouse | Warehouse items | ? | 11:30 | 12:05 | 35 min |
| 7 | Haz. Waste Storage — Rearrange | Various | 3,500 kg | 12:40 | 13:20 | 40 min |
| 8 | Haz. Waste — Tote Weighing | Totes | 1,400 kg | 13:50 | 14:25 | 35 min |
| 9 | Transfer Aisle / Yard | Pallets | 150 kg | 14:55 | 15:10 | 15 min |
| 10 | Metal Fab Paint Booth | Empty totes | 130 kg | 15:15 | 15:30 | 15 min |
| 11 | Yard — Pallet Arrangement | Pallets | 350 kg | 15:45 | 16:00 | 15 min |
MTC #0587Patio / Steel Yard · Aug 14 · Shift 1Gas~89% Utilization
| # | Route | Product | Weight | Start | End | Duration |
|---|---|---|---|---|---|---|
| 1 | Patio — Material Rearrangement | Various | 500 kg | 7:15 | 8:45 | 1:30 hr |
| 2 | Island Material Arrangement | Various | 500–1,000 kg | 9:10 | 10:30 | 1:20 hr |
| 3 | Unload Metal Cart | Scrap, angles, channels, beams | 500 kg | 12:08 | 12:36 | 28 min |
| 4 | Load Metal Cart | Steel scrap | 500 kg | 13:48 | 15:25 | 1:37 hr |
| 5 | Move Pallets from Generator Container | Wood pallets | 100 kg | 7:30 | 7:50 | 20 min |
| 6 | Move Crates | Standard parts | 500 kg | 8:10 | 8:40 | 30 min |
| 7 | Move Radiators | Radiators | 1,000 kg | 9:05 | 9:30 | 25 min |
| 8 | Incoming Box + Receiving Move | Various | 1,000 kg | 10:00 | 10:40 | 40 min |
| 9 | Unload Flatbed — Structural Steel | Channels, angles, beams | 2,000 kg | 11:10 | 12:15 | 1:05 hr |
| 10 | Unload Flatbed — Plates | Cal. 12 plates | 2,000 kg | 12:25 | 13:00 | 35 min |
| 11 | Unload + Load Metal Cart | Metal cart | 2,000 kg | 13:50 | 14:15 | 25 min |
| 12 | Load Metal Cart | Metal cart | 3,000 kg | 14:25 | 15:10 | 45 min |
| 13 | Supply Plates to Metal Fab | Plates | 3,000 kg | 15:20 | 15:35 | 15 min |
| 14 | Move Wooden Crates | Wood | 500 kg | 15:40 | 15:50 | 10 min |
| 15 | Move Aluminum Bars | Aluminum bars | 1,000 kg | 16:00 | 16:15 | 15 min |
MTC #9583Steel / Transfer · Aug 14 · Shift 1Gas~53% Utilization
| # | Route | Product | Weight | Start | End | Duration |
|---|---|---|---|---|---|---|
| 1 | Yard — Cardboard Move | Cardboard | 60 kg | 6:00 | 6:30 | 30 min |
| 2 | Yard — JBox Move | JBox | 500 kg | 6:30 | 7:00 | 30 min |
| 3 | Yard — Standard Part | Standard piece | 1,200 lbs | 7:18 | 7:30 | 12 min |
| 4 | Chemical Storage | Chemicals | 500 lbs | 7:40 | 7:50 | 10 min |
| 5 | Transfer Area | Copper pallet | 500 lbs | 9:30 | 9:38 | 8 min |
| 6 | Transfer Area | Copper/Aluminum bars | 500 lbs | 10:36 | 11:31 | 55 min |
| 7 | Guard House | Cleaning supplies | 250 lbs | 11:33 | 11:48 | 15 min |
| 8 | Metal Fab | INFRA tanks | 500 lbs | 11:50 | 12:05 | 15 min |
| 9 | Transfer Area | INFRA tanks | 500 lbs | 13:53 | 14:20 | 27 min |
| 10 | Transfer Area | Al/Cu bars | 500 lbs | 14:30 | 15:15 | 45 min |
| 11 | Receiving | Fans | 200 lbs | 15:25 | 15:35 | 10 min |
| 12 | Dog Bone Area | Pallet | — | 15:40 | 15:45 | 5 min |
| 13 | Yard | Lumber | 1,200 lbs | 15:50 | 16:00 | 10 min |
| 14 | Yard — Rearrangement | Various | 600 lbs | 16:05 | 16:20 | 15 min |
Reach Truck (Hombre Parado)Warehouse / Rack · Aug 14 · Shift 1⚡ Electric — 8hr charge~83% Utilization
| # | Route | Product | Weight | Start | End | Duration |
|---|---|---|---|---|---|---|
| 1 | Aisle 12 → Aisle 55 | Gasket | 200 lbs | 7:41 | 7:51 | 10 min |
| 2 | Receiving Area | Fans | 360 lbs | 9:20 | 9:30 | 10 min |
| 3 | Receiving Area | Fans | 360 lbs | 9:40 | 9:55 | 15 min |
| 4 | Receiving — Various Move | Various | — | 10:40 | 11:05 | 25 min |
| 5 | Receiving → Rack | Conductor wire | 1,500 lbs | 11:10 | 11:25 | 15 min |
| 6 | Receiving → Storage | Conductor wire | 1,100 lbs | 11:40 | 12:00 | 20 min |
| 7 | Receiving → Class 12 | Gasket | 200 lbs | 12:20 | 12:35 | 15 min |
| 8 | Steel Movement | Steel | 2,100 lbs | 12:55 | 14:00 | 1:05 hr |
| 9 | Conductor Arrangement | Conductor wire | 3,000 lbs | 14:20 | 14:55 | 35 min |
| 10 | Aisle 12 → Receiving | Conductor wire | 1,100 lbs | 14:55 | 15:10 | 15 min |
| 11 | Receiving → Rack | Conductor wire | 2,000 lbs | 15:30 | 15:50 | 20 min |
| 12 | Receiving → Aisle | Burras | 1,800 kg | 15:55 | 16:15 | 20 min |
| 13 | Receiving → Steel Aisle | Incoming load | — | 16:25 | — | In progress |
MTC #79563Receiving / Yard · Aug 14 · Shift 1⚡ Electric — 8hr charge~51% Utilization
| # | Route | Product | Weight | Start | End | Duration |
|---|---|---|---|---|---|---|
| 1 | Receiving Yard | Standard parts | 400 kg | 7:15 | 7:40 | 25 min |
| 2 | Main Aisle | Cable move | 300 kg | 7:45 | 7:50 | 5 min |
| 3 | Warehouse Yard | Duct move | 100 lbs | 7:59 | 8:04 | 6 min |
| 4 | Aisle | Copper bus | — | 8:04 | 8:10 | 6 min |
| 5 | Receiving Aisle | Bus bar | — | 8:25 | 8:30 | 5 min |
| 6 | Fan Move | Fans | — | 9:15 | 9:30 | 15 min |
| 7 | Yard | Wood spools | — | 9:20 | 10:00 | 40 min |
| 8 | Receiving Yard | Coil rolls | — | 10:12 | 10:33 | 21 min |
| 9 | Receiving Yard | REA unload | 800 kg | 10:35 | 10:44 | 9 min |
| 10 | Receiving Yard | Joistul unload | 500 kg | 11:46 | 11:54 | 8 min |
| 11 | Receiving Yard | Venum unload | 200 kg | 12:03 | 12:10 | 7 min |
| 12 | Receiving Yard | LGT unload | 2,000 lbs | 12:34 | 12:46 | 12 min |
| 13 | Receiving Yard | Chavez delivery | 2,400 lbs | 14:50 | 15:10 | 20 min |
| 14 | Receiving Yard | LTG unload | 400 lbs | 14:52 | 15:30 | 38 min |
| 15 | Production — Steel Supply | Steel | 1,400 lbs | 15:40 | 15:58 | 18 min |
| 16 | Shipping | Flexible conduit | 400 lbs | 16:00 | 16:10 | 10 min |
| 17 | Receiving — Import Unload | Imports | 500 lbs | 16:50 | 17:30 | 40 min |
Units Logged
4
All electric · 8-hr charge
Total Moves (Shift 1)
55+
Aug 18, 2026
Rented (Active)
2
MPU Shipping + Haz. Waste
Spare for Relocation
0
8-hr charge + 2 shifts = no buffer
MTC #60169Materials Area · Aug 18 · Shift 1⚡7:47 hrs active — 83% utilization
| # | Route | Product | Weight | Start | End | Duration |
|---|---|---|---|---|---|---|
| 1 | Receiving → Yard | N/A | — | 7:00 | 7:02 | 0:02 |
| 2 | Yard → MPU (pallets) | — | — | 7:30 | 8:00 | 0:30 |
| 3 | MPU → Yard (pallets) | Metal/wood pallets | 600 lbs | 8:00 | 9:30 | 1:30 |
| 4 | Yard → Industrial Waste Container | Waste boxes | 100 lbs | 9:30 | 10:00 | 0:30 |
| 5 | Container → Yard | — | — | 10:00 | 10:05 | 0:05 |
| 6 | Flatbed 1 → Yard | Brackets | 3,500 lbs | 10:30 | 11:00 | 0:30 |
| 7 | Yard → MPU Building | Radiators | 2,299 lbs | 11:10 | 12:20 | 1:10 |
| 8 | Flatbed 2 → Yard | Mixed material | 1,200 lbs | 12:30 | 13:00 | 0:30 |
| 9 | Yard → MPU (pallets) | — | — | 13:30 | 14:00 | 0:30 |
| 10 | MPU → Yard (pallets) | Metal pallets | 600 lbs | 14:00 | 15:30 | 1:30 |
| 11 | Order & Cleanup | Accessory pallets | 400 lbs | 15:30 | 16:00 | 0:30 |
| 12 | Yard → Chargers | — | — | 16:00 | 16:30 | 0:30 |
MTC #60168, #60167, and Reach #419 — Records available in source data
Additional equipment logs confirm 5:10, 6:10, and 5:30+ hours of active operation per unit in Shift 1 alone. With 2 shifts and mandatory 8-hour electric charging, zero spare capacity exists for redeployment to external warehouses.
Best data coverage — 2 full days, 3 units, 2 shifts
Minerales has the most complete dataset: Aug 12–13, 2026. 81 movements across 3 units. Fleet utilization: 94.2% (50:49 / 54:00 hrs). Only 3:11 hrs of spare capacity across all 3 units combined.
| Date | Shift | Operator | Route | Product | Weight | Start | End | Duration |
|---|---|---|---|---|---|---|---|---|
| Aug 13 | 1 | Fidel | Terrain → Warehouse | CL | 1,000 lbs | 7:20 | 7:28 | 0:08 |
| Aug 13 | 1 | Fidel | Terrain | TK (transformer) | 4,000 lbs | 8:14 | 8:32 | 0:18 |
| Aug 13 | 1 | Fidel | Flatbed Unload | Waste | 500 lbs | 9:45 | 10:29 | 0:44 |
| Aug 13 | 1 | Fidel | Flatbed Unload | CL | 1,000 lbs | 11:45 | 12:08 | 0:23 |
| Aug 13 | 1 | Fidel | Cleanup | Forklift | 3,000 lbs | 12:20 | 12:59 | 0:39 |
| Aug 13 | 1 | Fidel | Flatbed Load | TK + Scrap | 4,000 lbs | 15:40 | 16:22 | 0:42 |
| Aug 13 | 1 | Fidel | Flatbed Load | TK + AT | 4,000 lbs | 16:40 | 18:10 | 1:30 |
| Aug 13 | 1 | Mauro | Load Flatbed | Radiators | 2,000 lbs | 9:00 | 9:20 | 0:20 |
| Aug 13 | 1 | Mauro | Radiator Arrangement | Radiators | 2,000 lbs | 9:50 | 11:20 | 1:30 |
| Aug 13 | 1 | Alfredo | Esplanade → Terrain | TK | 4,000 lbs | 7:12 | 11:52 | 4:40 |
| Aug 13 | 1 | Alfredo | Load Flatbed | TK + AT | 4,000 lbs | 15:40 | 16:40 | 1:00 |
| Aug 13 | 1 | David | Terrain → Rework | TK | 4,000 lbs | 7:00 | 7:25 | 0:25 |
| Aug 13 | 1 | David | Incoming | TK + AT | 4,000 lbs | 8:06 | 8:27 | 0:21 |
| Aug 12 | 1 | David | Terrain → Rework | TK | 4,000 lbs | 7:30 | 7:55 | 0:25 |
| Aug 12 | 1 | Alfredo | Terrain Esplanade | AT | 3,000 lbs | 7:20 | 8:10 | 0:50 |
| Aug 12 | 1 | Alfredo | Terrain | TK | 4,000 lbs | 8:30 | 10:20 | 1:50 |
| Aug 12 | 1 | Fidel | Flatbed Load | AT | 3,000 lbs | 14:11 | 15:27 | 1:16 |
| Aug 12 | 1 | Mauro | Terrain | Radiators | 2,000 lbs | 12:40 | 14:40 | 2:00 |
Representative sample shown. Full dataset: 81 movements across 2 days and 4 operators.
Rented Reach HP-277: 93% utilization across full 18.5-hour operation day (T1+T2)
This single piece of rented equipment operates from 7:10 AM to 1:30 AM (18.3 hrs active). It cannot be removed due to dock height restriction. Its utilization data alone fully justifies the rental and supports a purchase decision.
Reach HP-277 — RENTED (P2 Contract)Industrias Warehouse · T1 + T293% Utilization — 14.5/18.5 hrs
| Shift | Route | Product | Weight | Start | End | Duration |
|---|---|---|---|---|---|---|
| T1 | Material Fulfillment | Raw Material | Variable | 7:10 | 10:00 | 2:50 hrs |
| T1 | Material Fulfillment | Raw Material | Variable | 10:30 | 14:30 | 4:00 hrs |
| T1 | Material Fulfillment | Raw Material | Variable | 15:30 | 16:30 | 1:00 hr |
| T2 | Material Fulfillment | Raw Material | Variable | 17:00 | 18:30 | 1:30 hrs |
| T2 | Material Arrangement | Raw Material | Variable | 19:00 | 21:00 | 2:00 hrs |
| T2 | Coil Arrangement | Conductor wire | 3,000 lbs | 21:00 | 23:00 | 2:00 hrs |
| T2 | Material Fulfillment | Raw Material | Variable | 23:00 | 24:00 | 1:00 hr |
| T2 | Steel Arrangement | Steel | 5,000 lbs | 1:00 | 1:30 | 0:30 |
| Total active | 14:30 hrs of 18:30 available = 93% | |||||
HP-277 Rented Reach — T1+T2 Combined Utilization93%
Physical restriction: dock too low — rented reach cannot exit normally
To move this equipment out of the warehouse a special platform is required and the unit must be laid on its side. This cost and logistics make routine relocation unviable. The 93% utilization data confirms that even if it could exit, there would be no economic reason to do so.
Single rented Reach (4,500 lbs) — no owned equipment assigned, dock restriction prevents relocation
Industrias 3 (Annex) is adjacent to Industrias main warehouse but does not share equipment. The dock clearance is too low for a reach truck to enter/exit without a special flatbed platform. The unit is permanently assigned inside the facility.
0
Owned Equipment at This Site
4,500 lbs
Rented Reach Capacity (P1 Contract)
❌
Normal Dock Access Available
Geographically isolated — transfer cost exceeds monthly rental
Llantera is a remote overflow warehouse at a separate geographic location. Moving a forklift there for each use (3–4 times/week) would require a flatbed transport each time. The cumulative cost of those transfers exceeds the monthly rental cost of the dedicated unit.
3–4
Weekly Movements Required
~25%
Equipment Utilization
7,000 lbs
Rental Unit Capacity (P1 Contract)
Recommendation: Monitor volume
If overflow inventory at Llantera decreases, consider consolidating to another facility to eliminate this rental. If volume increases, evaluate purchasing a dedicated unit.
💡 Recommendations
Action plan based on the capacity study findings — prioritized by urgency.
🔴 Purchase — Minerales Yard
Sit-Down Lift ≥4,500 lbs · Priority: IMMEDIATE
Minerales operates at 94.2% combined utilization across 3 units — there is virtually zero backup capacity. A single equipment failure would halt yard operations. Adding a 4th unit reduces utilization to ~71% and eliminates the rented unit.
94.2%
Current
~71%
With 4 units
81
Moves / 2 days
🔴 Purchase — Industrias Reach Truck
Replace HP-277 rented reach · Priority: HIGH
The rented HP-277 reach operates at 93% utilization across 18.5 hours/day. It is the highest-utilized unit in the entire fleet. A purchased replacement would stay permanently inside (dock restriction applies regardless of ownership), eliminating monthly rental cost while maintaining operations.
93%
Utilization
18.5 hrs
Daily operation
🟡 Keep Rental — Industrias 3 Reach
4,500 lbs Reach · P1 Contract · Priority: MEDIUM
Site has no owned equipment. Dock restriction makes any regular equipment transfer impractical. Long-term action: Evaluate dock door modification cost vs. 3–5 year cumulative rental cost. If dock can be raised, a smaller reach truck from the owned fleet could serve this site.
0
Owned units
❌
Dock accessible
🟡 Keep Rental — Plant 2 (MPU Shipping)
Sit-Down Lift · P2 Contract · Priority: MEDIUM
Continuous structural use for outbound shipping. Once P2 electric units are fully analyzed across both shifts, a purchase ROI calculation can determine the payback period. All P2 units are electric with 8-hr charging requirements, confirming no redeployment possibility.
🟢 Keep Rental — Hazardous Waste (P2)
Sit-Down Lift · P2 Contract · Regulatory
Handling regulated materials under PROFEPA requirements. This equipment cannot be shared with general warehouse operations due to cross-contamination risk. Rental provides operational flexibility for a dedicated regulatory asset.
🟢 Keep Rental — Llantera
7,000 lbs Sit-Down · P1 Contract · Geographic
Low utilization (~25%) but geographically isolated site. Each transfer by flatbed would cost more than the monthly rental. Watch inventory levels — if volume decreases significantly, consolidate to eliminate this rental.
| Priority | Site | Action | Type | Data Evidence | Impact |
|---|---|---|---|---|---|
| 1 — IMMEDIATE | Minerales Yard | Purchase 1 additional Sit-Down Lift | Purchase | 94.2% fleet utilization · 81 moves in 2 days | Eliminates rental + adds safety buffer |
| 2 — HIGH | Industrias Warehouse | Purchase reach truck (stays inside permanently) | Purchase | HP-277 at 93% utilization · 18.5 hrs/day | Eliminates highest-cost rental |
| 3 — MEDIUM | Industrias 3 | Evaluate dock door modification | Infrastructure | Dock restriction prevents equipment entry | Could eliminate rental if dock cleared |
| 4 — MEDIUM | Plant 2 | Evaluate purchase ROI for MPU Shipping unit | Purchase Analysis | Continuous structural use confirmed | Potential rental elimination |
| 5 — LOW | Llantera | Monitor inventory levels | Monitor | Low utilization · geographic isolation | No change now; reassess quarterly |
| 6 — STANDING | Plant 2 — Haz. Waste | Maintain rental | Mandatory | PROFEPA regulatory requirement | No change — legal obligation |