"Randim Stackum & Wrackem Inc - You pack it - We stack it"
If Andy's Pizza is to be used divide the layout at approx 1/3 - 2/3 with the 1/3 part being "Rest of the World" from which loads arrive and loads are sent to and the 2/3 part becomes the storage area with the pallet racking and the forklift truck.
The forklift is designed to handle pallets that are approx 4.5" (110mm) by 2.5" (60mm). The tines are fixed at about 3.5" (75mm) apart. So the pallet racking bays should be about 120mm by 60mm by 50mm high say.
Rolling stock consists of a small 4-wheel diesel(choose you own design) and 2 Bachman On30 flatcars (160mm by 50mm approx deck dimensions) with with stakes removed, and with steps and handbakes either removed or replaced with larger scale items. The loco is positioned between the flatcars.
Each bay is assigned a number 1-through to 6 with 2 spare bays. Start with at least 3 of the assigned bays loaded with items on pallets
How it works - The Randim part - use a dice (either electronic or old style) to determine where the load on the first flatcar is to be racked. The forklift gets the load and places it in the correct numbered rack (the Wrackem part). If the assigend rack is already taken, the load is to be placed in one of the "Spare" locations(the Stackem part). Repeat for second flat car.
You now have 2 empty flatcars to be loaded - Roll the dice to determine the load in which rack is to be loaded on the flatcars then taken back stage for off loading. Repeat for second flatcar If an empty rack is selected then roll again - the train must leave full.
After the train leaves for the "rest of world" backstage, any loads in the spare racks are to be spotted in any of the numbered racks by the forklift.
Meanwhile backstage, either manually swap the loads of the flatcars for different loads or send the same loads back out to the storage area - (Your choice).
Send the train out to the storage area, and start the cycle again.
Some examples of pallet loads:
1 Tarped boxes - variable sizes up to approx 100x50X50mm
2 Horizontally mounted drums on pallet
3 Vertically mounted drums on pallet
4 Lengths of metal rounds, pipes or sections etc keep different shapes on different pallets
5 large cylindrical tank(s)
6 pallet of metal plates or tmber with layers seperated by dunnage.
7 pallets of any of the "printies" - make sure you add some weight so that the load doesn't bounce when being handled by the forklift.
8 "Dangerous" loads with suitable signage.
My feeling is that you will need 6 to 10 different looking loads. Some of the "rest of world" loads could be stored in racks attached to the back of the dividers so they are not visible from the storage area.
Ok that'll do for now.
Now to see whether I can draw it up Andy.