Modern Materials Handling
Transcription
Modern Materials Handling
PRODUCTIVITY SOLUTIONS FOR DISTRIBUTION, WAREHOUSING AND MANUFACTURING mmh.com ® June 2012 RADIOSHACK: Making the little things count 16 INFORMATION MANAGEMENT Manufacturing intelligence 22 Jack Harwell, vice president of global sourcing and distribution operations, RadioShack EQUIPMENT REPORT Shuttle technology 28 BEST PRACTICES Automotive: Lineside delivery explored 34 Attend Modern’s Virtual Conference State of Materials Handling Automation June 28, 2012 @ 11:00 a.m. EDT Register: www.supplychainvirtualevents.com FREE Industry Resources Stay connected between issues. Email Newsletters Online Like us on Facebook Magazine Follow us on Twitter Customer Service RSS Feeds White Papers P.O. Box 1496 • Framingham, MA 01701 Blogs Webcasts THE CORRUGATED REVOLUTION HAS ARRIVED. Introducing the Packsize® iQ FUSION™. The Packsize iQ FUSION™ is a multi-patented, automatic packaging machine designed to bring the benefits of On Demand Packaging™ to a wider range of companies than ever before. With On Demand Packaging™ you can save an average of 35% in packaging costs by making the right-sized box, eliminating filler material, minimizing damages, and reducing shipping charges. Learn more at packsize.com WHAT IS ON DEMAND PACKAGING™? watch the video at packsize.com UP FRONT Breaking news you should know SAP to acquire Ariba Taking large steps to expand its presence in the cloud, ERP giant SAP announced that its subsidiary, SAP America, has entered into an agreement to acquire Ariba, a 15-year-old, cloud-based supply chain management technology provider for roughly $4.3 billion. The deal is expected to close in the third quarter. SAP officials said that by bringing Ariba, the leader in cloud-based collaborative business commerce, into the fold, it “establishes SAP as the leading 3PL market shows gains Data from supply chain consultancy Armstrong & Associates showed that total global third-party logistics (3PL) gross revenue in 2011 at $133.8 billion was up 5.2% over 2010. Net revenues, at an estimated $61 billion, posted a 5.9% annual gain. Armstrong said that domestic North American transportation and value-added warehousing had strong years, while a still difficult economic environment in Europe and a “cooling” Asian economy tempered results in those locales. Armstrong & Associates chairman Dick Armstrong said in an interview that this growth pattern in the global 3PL sector should remain intact over the next few years even with various global economies, including Asia, Europe and Brazil, continuing to have difficulties. IFCO opens RPC service center IFCO Systems U.S. announced the grand opening of its newest reusable plastic container (RPC) Service Center in Portland, Ore. The new facility is IFCO’s fifth U.S. service center, extending the company’s network in North America in support of the continued expansion of RPC use by leading grocery retailers throughout the U.S. and Canada. The 85,000-squarefoot facility washes more than 40,000 RPCs per day, and ships and receives approximately 25 to 40 truckloads of RPCs daily for IFCO’s grocery retail partners and grower shipper customers. To meet the demand in the Northwest, IFCO’s Portland service center is expected to employ more than 100 employees. Smart Packaging Systems earns DuPont Award for innovation FAS T FACT Smart Packaging Systems, an Austin, Texas-based company, has been cited for excellence in the DuPont Awards for Packaging Innovation. Smart Packaging Systems won the award for The Cube, a transport packaging system that enables companies to move their products from factory to store with maximum efficiency and full protection of the product. The Cube is designed to go from product pack-out at the end of a manufacturer’s production line into distribution, be it national or international, in any mode of transportation, straight to the retailer sales floor. “While every part is recyclable, the units are reuseable and transformable throughout the supply chain to insure that nothing hits a landfill,” says Darryl Kelinske, CEO for Smart Packaging Systems. mmh.com business network, adding business-tobusiness collaboration to its existing solutions.” The company added that this deal will mesh Ariba’s buyer-seller collaboration network with SAP’s broad customer base and deep business process expertise to create new models for businessto-business collaboration in the cloud. 30% Amount of the manufacturers that have fully automated data collection processes for metrics related to manufacturing efficiency. See story, p. 22. Source: “Pursuit of Performance Excellence,” a research report by the Manufacturing Enterprise Solutions Association (MESA) International and Cambashi Modern Mat eria l s Ha ndl ing / J u n e 2012 3 Automated Warehouse Solutions Partnership. Innovation. Creating Supply Chain Solutions. System Logistics offers a full line of automated material handling systems to make your distribution or manufacturing operations more productive, more efficient and more profitable. In today’s business environment, your material handling system has a small margin of error; you have to get your orders out the door fast and you have to get them right. Thanks to a wide range of technologies and a broad experience gained in many markets and geographical areas, System Logistics is able to develop any kind of project with you to make our world of expertise and technologies become your best fitting solution for: •Split Case Picking •Full Case Picking •Buffering and Sequencing •Automated Storage and Retrieval Systems Think Accuracy Think Productivity Discover System Logistics Your easy, efficient, economic picking solution System Logistics Corp 888-233-6796 [email protected] www.systemlogistics.com VOL. 67, NO. 6 ® PRODUCTIVITY SOLUTIONS FOR DISTRIBUTION, WAREHOUSING AND MANUFACTURING Jack Harwell, vice president of global sourcing and distribution operations, RadioShack COVER STORY SYSTEM REPORT 16 RadioShack: Making the little things count A new mezzanine reduced the space required for picking small parts and accessories by two-thirds while improving productivity. 20 Mitigating risk The new pick module features motor-driven roller conveyor, lightdirected picking, and an intelligent warehouse control system that enables zone skipping for more efficient picking operations. FEATURES INFORMATION MANAGEMENT 22 Getting manufacturing intelligence Manufacturers are managing by data rather than instinct. The next generation of MES systems is helping them get there. EQUIPMENT REPORT 28 Automated storage: Shuttle technology is taking off From unit loads to mini-loads and now micro-loads, automated storage and retrieval systems are evolving to effectively manage the changing needs of today’s order fulfillment operations. BEST PRACTICES 34 Automotive: Make lineside delivery count It’s been a rough road for the automotive industry, but production is increasing. To keep pace, auto manufacturers are focusing on lineside delivery strategies that get the right product to the right operator at the right time. PRODUCTIVITY SOLUTION 40 Workstation bridge crane handles big jobs for small machine shop 41 Crane handles lifting of heavy metal 42 Feed Commodities increases storage mmh.com 60 seconds with..Don DeSanctis DEPARTMENTS & COLUMNS 3/ Upfront 7/ This month in Modern 12/ Lift Truck Tips: Mobile computing 14/ Packaging Corner: Stretchwrapping 44/ Supplement: Four trends in mobility 50/ Focus On: Dock Equipment 55/ Product Showcase 58/ 60 seconds with... NEWS 9/ Changes in commerce affect distribution networks and processes 10/ Industry recognized among top 250 U.S. trade shows 11/ Gartner releases annual Supply Chain Top 25 list Modern Materials Handling® (ISSN 0026-8038) is published monthly by Peerless Media, LLC, a Division of EH Publishing, Inc., 111 Speen St, Suite 200, Framingham, MA 01701. Annual subscription rates for non-qualified subscribers: USA $119, Canada $159, Other International $249. Single copies are available for $20.00. Send all subscription inquiries to Modern Materials Handling, 111 Speen Street, Suite 200, Framingham, MA 01701 USA. Periodicals postage paid at Framingham, MA and additional mailing offices. POSTMASTER: Send address changes to: Modern Materials Handling, PO Box 1496 Framingham MA 01701-1496. Reproduction of this magazine in whole or part without written permission of the publisher is prohibited. All rights reserved. ©2012 Peerless Media, LLC. MODERN MAT ERIA L S HA NDL ING / J U N E 2012 5 www.hyundai-ce.com Moving you further! HYUNDAI FORKLIFT TRUCKS FORKLIFT LINE -UP LPG Forklift 1.5 ~ 5.0Ton Diesel Forklift 1.5 ~ 25Ton Battery Forklift (Counter Balanced) 1.6 ~ 5.0Ton Electric Order Picker 10BOP-7 / 13BOP-7 Reach Truck (Pantograph) 1.5 ~ 2.3Ton Reach Truck (Standing) 1 ~ 2.5Ton Reach Truck (Seated) 1.4 ~ 2.5Ton Electric Towing / Platform Truck 40TA-7 / 15PA-7 HEAD OFFICE(SALES OFFICE) 14th FL., Hyundai Bldg. 75 Yulgok-ro, Jongno-gu, Seoul, Korea Tel. 82. 2. 746. 4753 / 4609 Fax. 82. 2. 746. 7444 / 7445 E-mail. [email protected] This month in ® modern EDITORIAL OFFICES 111 Speen Street, Suite 200 Framingham, MA 01701-2000 (800) 375-8015 Michael Levans Group Editorial Director [email protected] Bob Trebilcock Executive Editor [email protected] Noël P. Bodenburg Executive Managing Editor [email protected] Lorie King Rogers Associate Editor [email protected] Sara Pearson Specter Editor at Large [email protected] Roberto Michel Editor at Large [email protected] Josh Bond Editor at Large [email protected] Jeff Berman Group News Editor [email protected] Mike Roach Creative Director [email protected] Wendy DelCampo Art Director [email protected] Daniel Guidera Illustration [email protected] Brian Ceraolo Group Publisher [email protected] Peerless Media, LLC A Division of EH Publishing, Inc. Kenneth Moyes President and CEO EH Publishing, Inc. Brian Ceraolo Publisher and Executive Vice President Peerless Media, LLC MAGAZINE SUBSCRIPTIONS Start, renew or update your FREE magazine subscription at www.mmh.com/subscribe. Contact customer service at: Web: www.mmh.com/subscribe Email: [email protected] Phone: 1-800-598-6067 Mail: Peerless Media P.O. Box 1496 Framingham, MA 01701 eNEWSLETTER SUBSCRIPTIONS Sign up or manage your FREE eNewsletter subscriptions at www.mmh.com/enewsletters. MICHAEL LEVANS GROUP EditorIAL DIRECTOR Automation insight is just a click away T here’s a significant trend that has been unfolding over the first half of the year that’s given me hope that the economy has finally turned the corner: Professionals representing all facets of supply chain management are starting to step out of their facilities and offices to attend live trade shows and events. For me, it started in February when 20,000 attendees descended on Atlanta to visit Modex. And the good news continues to unfurl month after month as the staff of Modern Materials Handling and our sister publications report back from conferences and shows in all corners of the country. Attendance is finally picking up, and the buzz surrounding facility investment, automation upgrades and future planning are generally upbeat. While live attendance numbers are certainly on the upswing, the live event business is still falling well short of pre-recession levels. While many have been given the “green light” to move forward on an upgrade or new project, those attendance figures signal that the majority remains tethered to their facilities, weighed down by the recession’s mantra of doing more with less. Travel may be back in the budget, but many simply don’t have the time. It’s for these folks that we’ve designed Modern’s upcoming “State of Materials Handling Automation,” a half-day, virtual conference where a select team of materials handling analysts, consultants and practitioners share how today’s leading supply chain organizations are leveraging automation to improve facility operations and streamline overall business strategy. The event will be sharply focused on the revolutionary impact that multi-channel fulfillment is having on materials handling Member mmh.com Member of automation and overall operations. In today’s emerging, multi-channel environment, flexible retail warehouse and DC operations are now handling a variety of functions out of one facility—direct-to-consumer order fulfillment, store replenishment, wholesale distribution, and global distribution. And, of course, any retailer worth its salt today has to fill orders in all of these channels, even though each has distinct order profiles, order quantities and inventory requirements. The challenge to both retailers and systems integrators has been immense—and from what we’ve seen, the best have been equal to the task. In our effort to offer a complete overview of the multi-channel effect, executive editor Bob Trebilcock opens the event with his Keynote that summarizes his conversations with leading systems integrators and their forecast for how materials handling automation will evolve to meet the multi-channel challenge. Conference sessions will then dive into goods-to-person order fulfillment and its role in multi-channel retailing; how warehouse management systems and warehouse control systems are now collaborating to better manage the release and flow of multi-channel orders; and we’ll wrap up with a look at the rise of AGVs and automated storage and retrieval systems and the critical part these technologies are playing in next-generation fulfillment. So, if you’re anxious to gain more insight into the latest developments and applications of materials handling automation and you don’t have the time to leave the facility, I have good news for you. You don’t have to catch a flight. You just need to click here: supplychainvirtualevents.com. Winner Jesse H. Neal Certificates of Merit for Journalistic Excellence Official Publication of Modern M aterials Handling / J u n e 2012 7 We tune all makes and models. Cost. Safety. Function. Performance. Any reason you need to modernize your supply chain assets is a perfect reason to do it with Dematic. With more than 9,000 modernizations performed on both Dematic and non-Dematic system installations, no other company can match our experience and commitment to the aftermarket. That vast experience means less risk for you. We’ll perform a thorough equipment audit or modernization study. Then work with your staff to develop a cost-effective solution. And commit to a timeline you can count on. From a minor improvement like replacing a floor rail in your storage and retrieval system over a weekend, to a major modernization like upgrading your entire control system. No one delivers like Dematic. http://www.dematic.com/na/customer-service Follow Modern Online facebook.com/mmhmagazine Twitter | @modernmhmag Web | mmh.com RETAIL Changes in commerce affect distribution networks and processes REPORT SHOWS THAT RETAILERS ARE LEVERAGING A MULTICHANNEL APPROACH TO MEET BUYER EXPECTATIONS AND COMPETE FOR MARKET SHARE. BY JEFF BERMAN, GROUP NEWS EDITOR THE ONGOING UPSWING in ecommerce and mobile commerce activity continues to make a significant impact on how retailers, distributors and third-party logistics (3PL) approach distribution network processes, according to a new report from global real estate firm Jones Lang LaSalle (JLL). In its report, entitled “Retail 3.0: The evolution of multichannel retail distribution,” JLL noted that retailers are leveraging a multi-channel approach to meet buyer expectations and compete for market share. In addition, about 80% of retailers said online sales have gone up in the last five years, with some saying they are up by as much as 25%. This increase has led to retailers modifying traditional distribution networks to better match up with how they handle e-commerce-related business. “E-commerce was on the radar screen five to 10 years ago, but people were not really doing anything about it,” said mmh.com Kris Bjorson, managing director of JLL’s Retail/e-commerce Distribution Group. “But now, everyone has some type of plan around it.” These plans can vary, though, with retailers letting third parties, such as GSI Commerce, handle things, or retailers building out their own e-commerce distribution net- work that they independently own and operate, he said. Across the retail spectrum, Bjorson told Modern that companies are at opposite ends of extremes and trying to define their multi-channel strategies—when determining how to implement them inside or outside of their own distribution networks. These implementation steps are wide ranging, with some retailers expanding networks through acquisition, as was the case with Walgreens acquiring drugstore.com, or Bed Bath & Beyond opening up multiple MODERN MAT ERIA L S HA NDL ING / J U N E 2012 9 e-commerce DCs. These steps are vital as retailers are meshing new shopping channels to add complexity and flexibility into their supply chains, said Bjorson. This entails taking steps to do things like reconsidering store footprints and total inventory levels. In the report, JLL noted that retailers are seeing more cost-effective advantages to boost online logistics operations over opening up new brick and mortar locations. One way of doing this is to augment regional distribution networks by rolling out e-commerce distribution centers. But these centers also require more of a capital investment, as ecommerce DCs center around direct order fulfillment, are more costly, and require more staff. “In terms of supply chain improvements, it is really all about speed as it relates to productivity and picking individual items, like with Amazon.com buying Kiva Systems,” said Bjorson. “Using this type of [robotic] technology helps Amazon quickly process an order and box it up and send to a consumer who needs it tomorrow. Speed drives service. Retailers need to have facilities located close to UPS or FedEx ground locations because consumers want next-day delivery of their orders.” This subsequently forces retailers to think about the design of their facilities to make sure they are quickly picking individual items and have enough dock doors and trailer space to re-circulate trucks, he said. To successfully do this, retailers need to be nimble and flexible with their “inside the box” operations and have a fluid transportation network set-up intact. And with inventory management crucial for supply chain management processes, technology is a linchpin for speed and efficiency from point of sale to the inventory fulfillment mechanism. “Technology is where you talk about evolution in the e-commerce distribution world,” said Bjorson. “One of the big requirements is a technology investment. From technology it goes down to the materials handling level as the next big investment in terms of importance, with real estate further down.” EVENTS Industry recognized among top 250 U.S. trade shows PROMAT 2011 AND PACK EXPO Las Vegas 2011 have been named to the 2011 Trade Show News Network’s (TSNN) U.S. Top 250 Trade Shows list. This list represents the top 250 trade shows held last year in the U.S. ranked by net square footage. Pack Expo, sponsored by PMMI, ranked 23rd, measuring 627,853 net square feet, expanding 30.5% from the show’s 2009 previous edition. ProMat 2011, sponsored by the Material Handling Industry of America (MHIA), was ranked 80th. “Being recognized on such a prestigious list is not only a great accomplishment, but a great reminder that ProMat continues to be the largest and most relevant event in the material handling, supply chain and logistics field in North America,” said Tom Carbott, MHIA’s senior vice president of exhibitions. “We’re thrilled to SUPPLY CHAIN Gartner releases annual Supply Chain Top 25 list Given that “innovation” was the overriding theme of Gartner Supply Chain Executive Conference held in Palm Desert, Calif., it came as little surprise that Apple was lauded for its remark- Gartner Supply Chain Top 25: 1. Apple 2. Amazon 3. McDonald’s 4. Dell 5. P&G 6. The Coca-Cola Company 7. Intel 8. Cisco Systems 10 J U N E able achievements this year. Gartner released the findings from its eighth annual Supply Chain Top 25 with Apple securely nestled in its position at the top again. 9. Wal-Mart Stores 10. Unilever 11. Colgate-Palmolive 12. PepsiCo 13. Samsung 14. Nike 15. Inditex 16. Starbucks 17. H&M 2 0 1 2 / MO D E RN MATE R IALS HAND L I NG The goal of the Supply Chain Top 25 research initiative is to raise awareness of the supply chain discipline and how it impacts the business. 18. Nestle 19. Research In Motion (RIM) 20. Caterpillar 21. 3M 22. Johnson & Johnson 23. Cummins 24. HP 25. Kimberly-Clark mmh.com PMMI is using the same strategy for Pack Expo International 2012 (McCormick Place, Chicago; Oct. 28– 31). The three pilot markets targeted in 2011—confectionery, baking/snack and pharmaceutical—will be joined by a fourth market, beverage. TSNN is an online resource and authority for the trade show, exhibition and event industry. The organization operates an event database that includes more than 19,500 trade shows, exhibitions, public events and conferences. A full list of TSNN’s top 250 trade shows can be found at TSNN.com/datasite. Loading Dock Safety YES! Lost Time Folding-Rail Gate Accidents NO! be included again this year and are looking forward to an even more successful ProMat event in 2013.” Pack Expo 2011 broke all records. Visitor attendance went up 14.8%, exhibiting companies increased by 36.7%, and international attendance increased by nearly a third (32.8%). The secret, PMMI’s vice president of trade shows Jim Pittas says, is in the approach. In 2011, PMMI debuted a customercentric approach to the show. “Taking a customer-centric approach to Pack Expo means looking at and planning the show from the perspective of the attendee—our members and exhibitors. It’s a focus on specific attendee markets that is seen in marketing material, on the show floor, on our Web site and in programming,” Pittas said. “Clearly, it works for attendees and for exhibitors.” Looking ahead, both MHIA and PMMI have big events planned for the industry. ProMat 2013 (McCormick Place, Chicago; Jan. 21-24, 2013) will be the most comprehensive international materials handling, supply chain and logistics show and conference held in the United States in 2013. It will showcase the solutions of 800 exhibitors that will fill the 300,000-square-foot show floor. DOCK SAFETY SOLVED Protect personnel with EdgeGard™ Dock Gates. EdgeGard™ Gates are superior by design, easy to install, and even easier to operate. They help protect personnel from falling off wide truck pits and loading docks. The unique Folding-Rail Gate protects wider openings up to 12 ft., while minimizing the required gate clearance height. A Straight-Rail Gate easily handles standard openings up to 10 ft. Straight-Rail Gate Say YES to loading dock safety and NO to lost time accidents with a Wildeck EdgeGard™ Gate. It’s a level of quality and craftsmanship you won’t find anywhere else. 800-325-6939 or WILDECK.COM STORING Get the most out of your space LIFTING Move inventory with ease mmh.com GUARDING Protect your facility ©Wildeck, Inc. 2012 MODERN MAT ERIA L S HA NDL ING / J Wildeck_EdgeGard_HalfPgIsl_MMH.indd 1 U N E WEDG 1205 AD 2012 11 4/30/12 12:38 PM lift truck TIPS Tablets break free of the fixed mount Ruggedized mobile computers improve productivity on or off the lift truck. By Josh Bond, Editor at Large A s technology rapidly improves, on-board computing has added incredible productivity and visibility for lift truck fleets everywhere. However, the pace of that improvement has some customers concerned that they will be left with obsolete computer equipment within a few years. Given the intensity of many lift truck applications, customers also wonder if new computing equipment will hold up or result in costly and time-consuming repairs. Mark Holleran, president of Xplore Technologies, says recent improvements in durability, modular component design, and user interface are enabling customers to get even more from their on-board computers while ensuring a productive future. The current trend in warehousing/ distribution, says Holleran, is to move away from fixed-mount devices to more mobile platforms. “If, say, 20% of the fleet is down at any given time for charging, repair or off shift, the device is also down,” says Holleran. “Similarly, if the computer is down, then so is the lift truck.” With easily detachable on-board computers, the customer can purchase and maintain fewer devices. This kind of flexibility can even enable devices to serve a number of purposes in a facility, says Holleran, from wall-mounted time clocks to GPS units. Holleran says the second key shift in mobile computing is the preference for tablet-style computers with touchscreens. Customers want stylus and touch capability, and studies show that the intuitiveness of touch interfaces increases data accuracy, says Holleran. An additional benefit of the widespread use of tablets is the ease of training. “To some extent, training for these devices and their software is built into the ambient culture,” he says. Customers want to be able to do on-site repairs for 12 Ju n e 2 0 1 2 / M ode rn M at e ri als H an d li n g things like hard drives and ports that become damaged, he says. Some tablets now offer tool-less hard drive removal, tool-less access to the SD memory card, and as little as four screws to access the memory chips. These features allow for quick upgrades, repairs and data transfers in the field. Durability is also essential, says Holleran. Units should have a minimum five-year lifespan, he says, as compared to an 18- to 24-month rotation cycle for desktop computers. Unlike desktops, industrial tablets must contend with industrial environments, like rough floors and minimal suspension. “You need industrial-class components, not just a hard shell on a consumer-grade product,” says Holleran. “They call those products ‘semi-ruggedized,’ but customers need real-world rugged.” Josh Bond is an editor at large for Modern and can be reached at [email protected]. mmh.com WHEN YOUR PALLET JACKS AREN’T WORKING, YOUR OPERATORS AREN’T EITHER. THAT DOESN’T WORK FOR YOUR SCHEDULE. OR YOUR CUSTOMERS. THE RELIABLE, HARDWORKING PALLET JACKS THAT WON’T LET YOU DOWN. PROBLEM SOLVED. 12YLE5275 We pushed our heavy duty pallet jacks to the limit—1000+ hours in an extreme cold storage application test, emptying 1,300 trailers, moving 50,000 pallets and transporting 105,000,000 lbs. of freight—without lubrication or service. Just the dependability that you’d expect from a world-class manufacturer like Yale. Of course, we don’t recommend you treat your trucks this way. Always follow recommended maintenance intervals. Find out more at Yale.com. Yale is a Registered Trademark. is a registered copyright. ©Yale Materials Handling Corporation 2012. All Rights Reserved. packaging corner How to pick the right stretch wrapper By Sara Pearson Specter, Editor at Large W hen applying stretch wrap to a unit load, many facilities rely on manpower. But wrapping by hand has its downsides, increasing the risk of worker injury and inefficiently using stretch film, says Steve Fleming, director of sales at the Wulftec/M.J. Maillis Group. “Based on film costs alone, a machine can be justified within two years for a facility currently hand wrapping as few as 10 loads a day,” Fleming adds. “Plus, there are ergonomic and sustainability benefits.” In addition to removing the worker from the process, stretch wrapping machines use rollers that pre-stretch film by three to four times before applying it. The load is more consistently secured with up to 50% less film. “Film is a petroleum product, and its cost has increased roughly 15% since January 1,” says Fleming. Using a return on investment calculator will help determine the potential savings from a switch. Those cost savings, says Fleming, often prompt a machinery purchase. The two basic styles are turntable, which rotates the loads as a static applicator feeds the film, and rotary arm, that uses a carriage that revolves around the load to apply the film. To pick the right stretch wrapper for your application, consider the following: 1. Load configuration. Unstable loads—mixed pallets or column-stacked (instead of interlocked) cases, for example—are not stable enough to be rotated on a turntable stretch wrapper. Facilities that wrap multiple types of stable and unstable loads would benefit from the versatility offered by a rotary arm model as well, even though they’re more expensive than turntables. 2. Load weight. Turntables have a top weight capacity from 3,000 to 5,000 pounds, says Fleming, so loads weighing that much or more will produce a lot of wear 14 J u n e 2 0 1 2 / Mo d e rn Mate r ials Hand l i ng and tear on the turntable’s drive system. Alternately, loads under 500 pounds are often too light for a turntable wrapper without special modifications that hold the load securely from the top. In both cases, a rotary arm model might be better. 3. Process. Wrappers are either fully automatic (selffeeding loads) or semi-automatic (loads placed by pallet jack or lift truck). Also, says Fleming, do you wrap loads throughout the day, or all at once at the end of a shift? Your process will help you pick the right machine. Sara Pearson Specter is an editor at large with Modern and can be reached at [email protected]. mmh.com Looking to boost DC productivity? Scan to see how RadioShack consolidated two DC’s into one super-efficient, smaller-footprint operation, or visit bit.ly/RadioShackMMH modern system report RadioShack A new mezzanine reduced the space required for picking small parts and accessories by two-thirds while improving productivity. By Bob Trebilcock, Executive Editor H ow many times have you heard that it’s the little things that count? Retailing giant RadioShack turned little things into a big business. The batteries, ear phones, cables and accessories that make personal electronics work are RadioShack’s signature products. “From a brand perspective, this is the core business that we are known for,” says Jack Harwell, vice president of global sourcing and distribution operations. “The signature products are also extremely important to our profitability.” It comes as no surprise then that a new pick module specially designed for those signature products has resulted in tremendous improvements at one of RadioShack’s two 600,000-square-foot distribution centers in Fort Worth, Texas. Working with a systems integrator (Intelligrated, intelligrated.com), the pick module features motor-driven roller conveyor (MDR), light-directed picking, and an intelligent warehouse control system (WCS) that enables zone skipping for more efficient picking 16 Ju n e operations. It has delivered significant operational improvements, including: • order accuracy of 99.9%, • a 100% increase in picking rates, and • increased SKU density by 75% to 1,800 SKUs. As an unexpected benefit, the picking software has provided a new level of visibility into the productivity of the workforce. That has allowed RadioShack to reduce the head count in signature parts picking by 42%. The module delivered those very big results in a 22,000-square-foot footprint that is two-thirds smaller than the 68,000-square-foot picking area it replaced. “Reducing the footprint of our picking area allowed us to consolidate our order fulfillment operations into one facility and free up a second DC to handle returns, repairs and the distribution or our fixtures,” says Harwell. Order selectors pick signature products from RadioShack’s new pick module. 2 0 1 2 / Mo d e r n Mate r ials Hand l i ng mmh.com makes the little things count Jack Harwell, vice president of global sourcing and distribution operations mmh.com Modern Mat eria l s Ha ndl ing / J u n e 2012 17 modern system report Quiet motor-driven roller conveyor transports cartons from the pick module to the packing stations. took up 68,000 square feet in one of the other buildings. The system averaged 150 lines per hour, per operator. It had other limitations as well. “The conveyance system was old, it ran all the time, and it was noisy,” says Hewett. “Plus, all of the totes from the old signature parts-picking module went to a pack out area with 39 packing stations. It took up a lot of space.” The old network RadioShack opened its first audio equipment showroom in 1947. Since then, the company has grown to nearly 4,500 U.S. stores operated by RadioShack Corp., more than 1,100 independently owned franchise stores, and 1,500 wireless mobile centers located inside Target stores. In addition, RadioShack operates 225 stores in Mexico and has international franchises in 29 countries. The stores are served by a distribution network that includes regional DCs in Hagerstown, Md.; Woodlawn, Calif.; and a joint facility in Fort Worth. “We had one 600,000-square-foot building in Fort Worth that was about 35 years old,” explains Dave Hewett, senior director of distribution. “And, in 1990, we built a second 600,000-square-foot facility in Fort Worth to take care of growth.” The Maryland and California facilities serve stores in their region. The Fort Worth facilities, on the other hand, not only serve regional stores, they are also the national distribution hub for select product lines, handle Web fulfillment for RadioShack.com, supply products to franchisees in foreign countries, and provide specialized labeling services, such as labeling in Arabic for a dealer in Egypt. Prior to this project, the network also included three additional facilities in Fort Worth for other processes such as returns, customer service, and repair and distribution of store fixtures. At that time, signature product SKUs were housed in a 20-year-old, lightdirected pick-to-tote operation that Toward a new design The seeds for the new module were sown in 2004. RadioShack commissioned a network study to address its changing distribution needs. It identified two weaknesses. First, the seven distribution centers, including two in Fort Worth, weren’t adequately serving RadioShack’s needs. Signature products distribution highlighted the inefficiencies in the existing network. “We were servicing about 5,700 stores from the old pick modules, and we were only able to make weekly deliveries to about 1,500 stores because at 150 lines per hour. We were at capacity,” says Hewett. That meant stores had to either carry extra inventory to make sure they had enough to get through until the next delivery, or they had to wait a long The pick module takes up just 22,000 square feet, two-thirds less space than the picking area it replaced. 18 Ju n e 2 0 1 2 / Mo d e r n Mate r ials Hand l i ng mmh.com period of time if they ran out. RadioShack also realized that clustering the chain’s most profitable products in one location known for extreme weather events created a significant risk. “Fort Worth is right on the edge of Tornado Alley,” says Harwell. “If a tornado wiped out that distribution center, we could be in a world of hurt.” The net result of that study was that RadioShack needed to consolidate its Fort Worth distribution activities to get more efficient. In addition, it needed to create a process to regionalize the distribution of signature products and mitigate risk. The new pick module addressed both of those objectives, but not without some work. “The old pick module was too big to move into one of the other DCs,” says Hewett. Instead, RadioShack decided to consolidate the signature products picking operation into an existing 22,000-square-foot pick module in one of the other buildings. To do that, “we had to reduce the physical footprint of the picking operations,” Hewett says. Several technologies were evaluated, including put-to-light and tilt-tray sortation solutions, before RadioShack chose the design recommended by its systems integrator. Two key features resulted in space and labor gains. One was the pick-tolight picking technologies. The other was zone-skipping technology that will only deliver a shipping carton to a zone where there are picks. “That reduced idle time of the pickers,” explains Randy Crowe, director of industrial engineering. Crowe adds that if a zone is full, the system software will automatically divert the carton to another zone with available work and then revisit the other zone later. “The carton is always moving,” he says. The old conveyor system was replaced with motor-driven roller conveyor technology. Now, conveyor is only turning when it has product to move, which saves energy. In addition, the MDR conveyor is much quieter than mmh.com Voice technology directs the picking operations in pick zones outside the signature product pick module. the older system. “In the old facility, it was hard to carry on a conversation with active picking going on,” says Hewett. Small footprint, big results Since going live, RadioShack has realized significant benefits. Average lines picked per hour have doubled. Associates’ average picking efficiency also doubled, with peak picking efficiency rates up as high as 165%. “As we get better at slotting and our people get more familiar with the system, we’ve been able to gradually draw down the labor in the picking module,” says Hewett. “That has let us transition people into other parts of the DC without increasing our head count. It’s a real continuous improvement process.” RadioShack plans to extend the robust WCS to other areas of the building. This will provide RadioShack with labor management functionality that it does not have in the proprietary warehouse management system (WMS). “We will be able to track the performance of individual pickers throughout the building,” Crowe says. “We have more visibility into our labor than we ever have before.” That information has been used to identify best practices that can be used to coach underperforming associates, or identify those associates who might be better suited to other tasks in the facility. “We have more visibility into our labor than we ever had before,” he says. Most important of all, RadioShack is realizing its broader network goals. Where it once had five DCs, all of its Fort Worth activities including returns, repairs and fixtures, have been consolidated into two adjacent facilities. More importantly, RadioShack is regionalizing the distribution of signature products, with new small parts pick modules that will go live this July in Maryland and California. “We’re going to have a higher level of service to our stores, which will allow us to ship every store on a weekly basis,” Harwell says. “And any one of the three DCs could ship on a national basis if necessary. That mitigates the risk of losing the Fort Worth DC to a tornado.” Similarly, the WCS will allow RadioShack to better manage the labor in the other two facilities as well. “That has been an absolute bonus that we discovered after we went live,” says Harwell. M Modern Mat eria l s Ha ndl ing / J u n e 2012 19 modern system report RadioShack Fort Worth, Texas Mitigating risk Size: 600,000 square feet total, of which The new pick module features motor-driven roller conveyor, light-directed picking, and an intelligent warehouse control system that enables zone skipping for more efficient picking operations. 25,000 square feet represents the new pick module and 95,000 square feet represents dedicated storage for the pick module Products handled: Small parts and pieces, such as electronics parts, batteries and accessories By Bob Trebilcock, Executive Editor Stock keeping units: 1,800 A new layout coupled with new technology has enabled RadioShack to reduce the space devoted to small parts picking while increasing productivity. The pick module is driven by its own receiving, replenishment, picking and shipping processes. Putaway/replenishment: Pick module replenishment is a paper-based replenishment process driven by the legacy warehouse management system (WMS). Orders that will be picked during the day are received into the WMS each morning. The SKUs and quantities required to fill the orders are matched against the amount of product already in the forward picking area (1). Stock move tickets are then automatically created to replenish any inventory that is below the quantity necessary to fill orders. RadioShack refers to these as auto move tickets. The auto move tickets are distributed to lift truck operators assigned to replenishment. The tickets direct them to the correct reserve storage location (2) to retrieve pallets or cartons required to replenish a forward pick location. Those items are then dropped off in a ready rack area—comprised of shelving located behind the forward pick locations designated for replenish- Throughput: 300 lines picked per hour from pick module Employees: 70 Shifts/Days: 1 shift/4 days per week ment. There, an associate transfers the product from the ready rack to the correct carton flow rack in a forward pick location. Picking: At the corporate level, an inventory management team reviews the current sales history for each store and a forecast for what the stores are expected to sell. Based on that review, the team creates replenishment orders for the stores served 2 Reserve storage Forward pick module 1 2 Reserve storage 3 Light-directed small parts picking Coveyor induction 5 3 4 Coveyor induction Voice-directed picking 4 6 Voice-directed picking Packing station Conveyor Conveyor 8 7 8 7 Merge Merge 9 Loading area 20 Ju n e 2 0 1 2 / M o d e rn M ate rial s Hand l i ng mmh.com MODERN system report by the Fort Worth facility. The goal is to make sure that each store is replenished in advance of the weekend, which is RadioShack’s busiest time. Orders are downloaded into the WMS each evening and are then passed to a transportation management system (TMS). To make a weekend replenishment schedule, orders are prioritized based on the transit times: Orders for the stores with the longest transit times are scheduled to be picked on Monday while orders with shorter transit times are shipped later in the week. The TMS also optimizes the orders, based on whether it is most economical to ship using a pooled distribution model, express freight or some other type of shipping mode. Once the TMS has optimized orders, they are passed back to the WMS and shipping labels are printed. Once the picking begins, shipping labels are placed on a carton which also includes a license plate bar code. The carton is automatically scanned when it is inducted onto the conveyor system (3) and delivered to the first zone where there is a pick. Consumer electronics and other products are picked from one of nine voice-directed picking zones (4). Signature products are picked from the light-directed small parts picking module in the center of the picking module (5). There, an associate scans the carton. The pick-to-light system then tells the operator which items and in what quantity are picked in that zone. Once the picks are complete, the system directs the associate to pass the carton to the next picker in the zone, or to push the carton onto a takeaway conveyor that will direct it to the next zone with a pick. Packing and shipping: Once all of the picks for that carton are complete, the last associate closes the carton and it is diverted to a takeway conveyor that delivers it to a packing station (6). There it is filled with any dunnage required for shipping and automatically taped. From there, the carton is merged (7) onto a conveyor system (8) feeding the loading area (9), where it is loaded directly into a truck. EXPORT PALLET SOLUTIONS AS LOW AS US$5.00 EACH Ə[ƏLQTXDQWLWLHV)2%RULJLQ EXPORT PALLET SHORTAGE FORECASTED T RY PRESSWOOD PALLETS CLEAN, DRY MOLD FREE IPPC-ISPM 15 EXPORT EXEMPT CROSS ANY BORDER COMMITTED TO EXCELLENCE SINCE 1962 LITCO INTERNATIONAL INC. 855-296-2891 www.litco.com fabric structures Sustainable Design-Build Solutions System suppliers SYSTEM INTEGRATION, MOTOR-DRIVEN ROLLER CONVEYOR, WCS, DIVERT AND ZONE-SKIP TECHNOLOGY, PICK-TO-LIGHT TECHNOLOGY: Intelligrated, intelligrated.com LIFT TRUCKS: Toyota, toyotaforklift.com; Raymond, raymond- FLEXIBLE FINANCE SOLUTIONS corp.com O N VOICE TECHNOLOGY: Vocollect, vocollect.com TERMS UP TO F A B R I C S T R U C T U R E S* 7 YEARS RATES AS LOW AS 4.99% AS LITTLE AS 10% DOWN *Subject to credit approval. BAR CODE SCANNING: Motorola Solutions, motorolasolutions.com TMS: Manugistics (JDA Software), jda.com DUNNAGE FILL SYSTEM: Ranpak, ranpak.com RACK SYSTEM: Pick module was retrofitted from existing rack WMS: Legacy system mmh.com Buildings available up to 300' wide. Low in cost per square foot. Natural daytime lighting. Easy to relocate. Expandable. Little or no property taxes. Call one of our ClearSpan specialists at 1.866.643.1010 or visit us at www.ClearSpan.com/ADMMH. MODERN MAT ERIA L S HA NDL ING / J U N E 2012 21 modern information management Getting manufacturing intelligence Manufacturers are managing by data rather than instinct. The next generation of MES systems is helping them get there. By Bob Trebilcock, Executive Editor 22 Ju n e 2 0 1 2 / Mo d e r n Mate r ials Hand l i ng mmh.com M anufacturing is in transition. The shop floor was once managed and monitored by instinct and experience. The manufacturing execution systems (MES) that manage manufacturing processes were transactional. The MES made sure that each of the steps in the manufacturing process, or transactions, were completed according to the rules for that process and the plan for that manufacturing run of product. They were also historical; the data about a shift often wasn’t reviewed until after a run was complete. Today, gut instinct and experience are slowly giving way to fact-based decision making supported by the next generation of real-time manufacturing software tools. At the best manufacturers, these systems are being employed to drive action down on the shop floor as it’s happening. They are also connecting the manufacturing plant back to the business at the corporate level. The transition is enabled by data collected by machine-level control systems and data capture technologies and analyzed by the MES. Much of that data has always been there, locked away in control system databases. Today’s MES and manufacturing-centric software systems have added the ability to unlock that data and turn it into metrics to measure and monitor what’s happening on the shop floor in real time. If required, that data can be linked to the business strategies being developed in the executive suite. The transition from instinct to metrics is highlighted in “Pursuit of Performance Excellence,” a research report released by the Manufacturing Enterprise Solutions Association (MESA) International and Cambashi last February. (A summary of the report can be found here: tinyurl.com/cco2tjk). “MESA members have been increasingly clear that the old way of manufacturing is no longer adequate,” says Julie Fraser, author, analyst and lead researcher of the report. “The question is: How do you create a metrics program that measures the right things that make a financial difference over time?” mmh.com The best manufacturers are collecting real-time data to monitor the metrics that make a difference in their operations. After all, there are thousands of things that can be measured in a manufacturing operation. Figuring out which ones make a difference and then measuring those all the way down the line to the operators and maintenance personnel is the key. “The companies that did manage to improve their business outcomes focused on improving on certain metrics more than other folks we surveyed,” Fraser says. Changing times A number of factors are driving this transition, according to Fraser and the software vendors that supported the study. Global competition has raised the bar in terms of quality and customer service. Correcting a mistake can cost you money, a customer and your reputation. Manufacturing is more complex than ever. Companies are releasing new products faster and in more configurations than ever before. In a global economy, country-specific regulations also impact the assembly line. “A product like the defibrillator used in airports, may get manufactured in a consumer and a medical version and each of those versions may be customers by language or country of delivery,” says Susan Lamb, senior manager of customer programs for Camstar. “Each of those variations is a divert on the line. Those complexities cannot be handled on paper.” With outsourcing and the distribution of manufacturing responsibilities across multiple sites, suppliers and countries, the manufacturing network is more complex than ever. Finally, there is more volatility. “Quite simply, the ground is shifting under the feet of most manufacturers,” says Fraser. “There is a lot less certainty from one week to the next whether orders are going to come in the way you thought they would.” That’s not to say that experience on the line doesn’t count. But, experience can only take you so far in a more complex environment. “You want to combine your gut with data and then refine what it is you’re measuring,” says Fraser. “It’s the ability to see the entire context of your business.” What’s more, that data needs to be provided across the business, from the C-level to the shop floor. While many world-class manufacturers are moving in this direction, Fraser says only a small percentage are there now. Among Modern Mat eria l s Ha ndl ing / J u n e 2012 23 modern information management the respondents to the MESA survey, a little more than 30% of the best manufacturers have fully automated data collection processes for metrics related to manufacturing efficiency. Just less than 20% of the best manufacturers were automatically capturing quality data. Among the remaining respondents, an estimated 15% were automatically capturing efficiency data and 10% were capturing quality data. Meanwhile, although they were capturing the data, only 25% of the best manufacturers were sharing it with line level operators and technicians while only 12% of the rest were sharing that data with their operations staff. Manufacturing intelligence This transition is reflected in the challenges manufacturers are presenting to manufacturing software providers. “Manufacturers are getting a lot of high-level data,” says Mike Gay, CPG industry manager for Rockwell Automation. “They’re not able to use it MES systems enforce quality into your processes, ensuring that every step is completed per the plan. at a more granular level.” A french fry maker, for instance, knows that it should cost $1.00 to make a unit of product and that the cost of production is running $1.10 at one particular plant. With current systems, that manufacturer can identify all of the raw materials going into a batch of product and quantify what it produced. What it can’t tell is what happened at the line that cost the extra 10 cents. “The plant may know that they’re getting a 40% Spirited manufacturing Mobile manufacturing technology accelerated performance at Diageo North America. Diageo may not be a household—or even a barstool—name. But Diageo brands such as Smirnoff, Johnnie Walker, Tangueray, Jose Cuervo and Sterling Vineyards are among the top selling wine and spirits labels around the globe. Thanks to continuous improvement initiatives, involving TPM, Lean and Six Sigma methodologies, Diageo had already brewed up a manufacturing culture focused on excellence. The wine and spirits operator implemented a real-time manufacturing intelligence system (Solarsoft) to capture and analyze real-time production metrics that would take its operations to the next level. The system monitors production by plant, production line, by machine, by SKU, by product family, or by 24 Ju n e line by time and day across North American operations. In all, the application is monitoring and analyzing 10,000 data points at any given time. That information is then analyzed by the software to identify the best improvement opportunities across the network of facilities as well as within a facility. To make it more user friendly, the information is distributed to management and plant personnel though an app on their iPads. Using that shop floor data, Diageo saw a 25% improvement in its operational efficiency in the first full year after going live with the solution. “The data gives our operations team and senior executives visual insight to tackle tough problems and propagate best practices,” says Ewan Andrew, senior vice president of manufacturing and distilling. ”Our focus now is to take this application and continue to build, sustain and multiply the improvements into the future.” 2 0 1 2 / Mo d e r n Mate r ials Hand l i ng yield from each load of potatoes that gets turned into fries,” Gay says, “but it doesn’t know what’s happening to the other 60% of the batch.” Similarly, the plant doesn’t know whether something in the washing and prep area affected what happened down the line, whether yield was lost when the finished product was packaged, or whether a quality problem caused the plant to scrap some of the product. “Rework and scrap are two of the biggest wastes in manufacturing,” says Lamb. “If you have real-time visibility and you enforce quality into your processes with an MES, you reduce those wastes and increase your yields.” In theory, MES have always been able to capture granular data. What they haven’t done is turn it into manufacturing intelligence. Nor have they integrated that manufacturing intelligence data into the broader business systems at the enterprise level. “To really improve your processes, you not only want to increase efficiencies in manufacturing, you want to view it in the context of the entire supply chain,” says Ganesh Hegde, senior director of manufacturing solutions marketing for SAP. For example, a manufacturer may be able to identify that one plant is continually underperforming other similar plants in the network when it comes to uptime, production rates or quality. Manufacturing intelligence allows the manufacturer to identify the problems affecting that plant. It also allows it to apply whatever was learned from this analysis to the next revision of the product or the next line. “You can loop manufacturing intelligence back into the design process so that the next generation of your product is improved,” says Lamb. But a problem may be a result of a larger issue in the network. “You may have good manufacturing processes, mmh.com Warehouse Racking Systems Selective Rack Drive-In / Drive-Through Push Back We manufacture Pallet Flow warehouse solutions. 866.632.2589 | www.interlakemecalux.com Cantilever modern information management but you are manufacturing the wrong mix of products at a location based on where the customers are for those products,” says Hegde. Similarly, a plant may be operating efficiently but quality is suffering because of an issue with a downstream process. “It’s not just taking intelligence from one particular plant, but integrating and analyzing that information in a more real-time fashion in a broader supply chain context,” says Hedge. Next generation tools Manufacturing software providers, including MES, are developing new tools to address the transition to fact-based decision making in a variety of ways. One is more dashboards that can deliver role-based operational metrics across an enterprise. Role-based means that the information being generated is pertinent to an individual based on their job. A C-level executive responsible for multiple plants may want information on finished goods being produced at each plant. Meanwhile, a supervisor or operator on the line may need throughput, rework or yield rates so they can make real-time adjustments to machines and equipment when performance metrics are out of line. A second is the creation of new tools that extend the capabilities of conventional controls, MES and ERP. One example is a cloud-based, unified manufacturing software platform that sits atop other systems. The platform collects information being generated by the underlying infrastructure of PLCs, devices and distributed controls systems that are running manufacturing equipment and systems. It also accesses information generated by disparate software systems within an enterprise. The solution then isolates the relevant information from those various systems to make critical business decisions at a role-based level. “The platform has the ability to connect to virtually any data source that a company has and pull data in sub- 26 Ju n e The next generation of manufacturing tools are utilizing dashboards that deliver role-based metrics across an enterprise. second times if required,” explains David Gustovich, president of iQity Solutions. A yeast manufacturer, for example, sends blocks of yeast across an inline scale at a rate of 32 blocks a minute, or nearly 2,000 blocks per hour. In a conventional plant, a quality inspector takes 10 blocks every 15 minutes to verify the weight on another scale and manually chart the weights on a control chart to make sure they are in compliance. If those blocks are out of compliance, the inspector may alert the line. Meanwhile, nearly 500 went across the line in that 15 minute period that may have to be reworked. “Instead, we connect to the inline scale and read every block in real time and apply rules to those data points to determine whether the product is in compliance in real time,” says Gustovich. “If they’re out of compliance, the system can proactively alert someone at the line level all the way to the C suite if required to take action.” Meanwhile, manufacturing-centric ERP systems are developing tools to connect the shop floor to the enterprise with analytical tools that identify issues related to overall equipment effectiveness. “We’re providing tools that monitor and measure whether machines are available when they should be, whether the line is making the quality of product that it’s supposed to make and whether 2 0 1 2 / Mo d e r n Mate r ials Hand l i ng the line is running as fast as it should run,” says Andy Amalfitano, vice president and general manager for Solarsoft. “The goal is to identify the top three losses in any organization, fix those and then make sure they stay fixed.” (See the sidebar on Diageo, p. 24, to see how one manufacturer put these tools into action.) As MES and other manufacturing software tools like these proliferate on the shop floor, Julie Fraser sees big improvements for early adopters. “The most successful companies have combined lean manufacturing practices with manufacturing software systems that give them visibility into their operations and put those metrics in a context and continually measure an outcome,” says Fraser. “Those are the manufacturers who were really able to improve their financials more than the rest of the pack.” M Companies mentioned in this article Cambashi: cambashi.com camstar.com iqitysolutions.com MESA International: mesa.org Camstar: iQity Solutions: Rockwell Automation: rockwellautomation.com SAP: sap.com Solarsoft: solarsoft.com mmh.com Your BEST Source for New Products in Materials Handling! Introducing MHPN.com Your daily source for new products Covering: • Mobile & Wireless • Lift Trucks & Accessories • Automation • Conveyors & Sortation • Containers & Totes • Packaging & Pallets • Dock Equipment • And much more! MHPN.com, Material Handling Product News’ new website, offers the most comprehensive listing of new products in the materials handling industry. Whether you’re looking for the newest innovations in dock equipment or the latest software to control your material flow in the warehouse, MHPN.com is your first stop. Check out MHPN.com today! www.mhpn.com modern equipment report Automated storage: Shuttle technology is taking off From unit loads to mini-loads and now micro-loads, automated storage and retrieval systems are evolving to effectively manage the changing needs of today’s order fulfillment operations. W By Lorie King Rogers, Associate Editor hen automated storage and retrieval systems first appeared on the materials handling scene back in the 1960s, they were designed and built to handle heavy pallet loads, known as unit loads. As automated storage and retrieval system (AS/RS) technology progressed, system incarnations were introduced to handle smaller, lighter loads in totes, trays, cartons and bins. This more compact cargo became known as mini-loads. Now, there’s another emerging storage technology known as shuttle technology, and it handles micro-loads. Like the mini-load AS/RS, shuttle technology is a computer-controlled system that uses moving vehicles known as shuttles to put away, store and retrieve goods in a racking structure. But while there are similarities, there are also differences between the two solutions. For example, two significant differences between a mini-load AS/RS and the newer shuttle technology are weight and directional movement. Both systems can transport product in totes, 28 Ju n e trays, cartons and bins, but the load handling devices in a mini-load AS/RS system are capable of carrying loads of up to about 1,000 pounds. Shuttle systems are designed to carry even lighter loads, typically limited to about 100 to 110 pounds. The mini-load AS/RS uses one stacker crane that moves horizontally and vertically, forward and back, and up 2 0 1 2 / Mo d e r n Mate r ials Hand l i ng and down an aisle. But in a shuttle system, two separate transport devices carry out vertical and horizontal movements. A lift, like an elevator, at one or both sides of the unit, moves up and down to the designated storage level within the system. Some lifts are designed to raise and lower more than one load at a time. Then, to move product horizontally— meaning to and from the lift and in and out of the storage aisle—each level is equipped with one or more load handling devices, or shuttles. “Shuttles and lift systems work independently from each other,” explains Roman Schnabl, product manager for Knapp USA. “This guarantees a maximum utilization of lift capacity and optimized throughput.” Another thing that makes the shuttle different from the typical mini-load crane is speed. Stephen Schwietert, Shuttle systems use a lift at the end of the unit to raise and lower loads. mmh.com Moving product in totes, trays, cartons and bins, shuttle systems are designed to handle loads up to about 110 pounds. mmh.com Modern Mat eria l s Ha ndl ing / J u n e 2012 29 modern equipment report integrated systems sales manager for TGW Systems, says shuttles can multiply throughput rates. “Because there can be a number of shuttles operating in a single aisle, and these shuttles are moving simultaneously, the throughput per aisle can be five to 10 times greater than a typical mini-load AS/RS,” he says. So while the vehicles act concurrently on different storage levels and a high throughput can be reached, typically it is the vertical lift at the end of the aisle that sets the limit for the possible throughput per aisle. However, according to Kenneth Hayer, senior consultant for Swisslog, there can be several lifts per aisle depending on performance requirements. Lifts can be located at the front, middle or end of an aisle. Still, the lifts also move at a fast rate. In fact, Hayer says that each lift can perform approximately 500 vertical lifts every hour and make it to the top of a 45-foot high rack structure in about three seconds. These differences give shuttle technology some advantages over a miniload system and can make it a better solution for certain automated materials handling applications. Here’s the answer, what’s the question? An AS/RS only brings value to an operation when an order is filled, says Dave Simpson, director of applications engineering for Schaefer Systems International. “It’s a holding tank for inventory, getting the right SKU to the right place at the right time.” So why do the features and benefits of shuttle technology make it a good materials handling solution for certain operations with certain requirements and not the ideal solution for others? The best way to understand the answer is to ask the question: What are you moving and why? If an operation that is handling a variety of goods in a variety of sizes, shapes and packages, shuttle technology could be the right match—especially if that operation is a warehouse or distribution center handling multichannel order fulfillment. Multi-channel order fulfillment is a term that we’re hearing a lot these days. Online shopping, smart phones, catalogs, 3:00 a.m. infomercials and brick and mortar stores offer shoppers more choices than ever. More options for consumers means a proliferation of SKUs for warehouses and distribution centers. It also means that more frequent and smaller orders are being shipped directly to individuals. Filling more small orders means a lot more leg work and that’s where shuttle technology steps in. The idea is to take the leg work out of order fulfillment and replace it with a goods-to-person strategy, which is supported by shuttle technology. “If an operation has products that are handled in case or unit quantities, and you have associates walking or riding to pick this merchandise, shuttles may eliminate the need for walking and increase productivity two to six times greater than your current process,” explains Schwietert. “This is where technology moves beyond the ‘wow’ factor, to a technology solution that integrates with an operation to deliver results.” With this solution, the integration Shuttle systems are a flexible materials handling solution that can accommodate consumer demand and serve as a holding tank for the ever increasing number of SKUs. 30 Ju n e 2 0 1 2 / Mo d e r n Mate r ials Hand l i ng mmh.com of shuttle technology results in getting orders to customers quickly and accurately. Shuttle technology supports goods-to-person order fulfillment configurations. According to Ken Ruehrdanz, warehousing and distribution market manager for Dematic, “shuttle technology supports higher order and inventory accuracy, increased productivity and controlled access to inventory.” It also accommodates the growing trend to improve the performance of the replenishment task, meaning the replenishment of inventory into the pick modules. The goods-to-person picking concept has gained traction over the past couple of years. “Because of their speed and ability to sequence, shuttles have opened up the idea of goods-to-person picking. Almost anyone with a traditional multi-floor pick module, may have an opportunity for goods-to-per- son picking using shuttle technology,” Schwietert adds. Conserving energy The demand creating the opportunity for this technology is a constant struggle to balance storage effectiveness, throughput capacity and SKU representation, Ruehrdanz says. When operations were only filling large orders for wholesalers or retailers, he points out, unit-load AS/RS systems were a fine solution. But unit-load systems that handle pallets are not as effective in this case. It’s comparable to using a service elevator to deliver a cup of coffee when you could have used a dumbwaiter Using shuttles to deliver product to the operators in a goods-to-person operation uses the right equipment to handle the job, and the shuttle’s lightweight design and advanced controls contribute to reduced energy consumption. In comparing the weight of miniload crane, which is about 20,000 pounds, to a shuttle carrier, which is less than 100 pounds, the difference is significant and so is the ratio of energy needed to move the load. The shuttle system has extremely low energy consumption at full speed. This is because carriers are driven by super capacitors and the system has energy recuperative features for both the carriers and the lifts that feed energy back into the system, Swisslog’s Hayer explains. Additionally, the control software continually optimizes transport routes and transport movements, making an added and important contribution to energy conservation. The interplay between lift system and shuttles makes a constant level of performance possible, avoiding energy consumption peaks and providing an YOU PERFECT IT. WE’LL PROTECT IT. Buckhorn offers an unmatched selection of reusable packaging solutions designed to protect your products and increase your profitability. Buckhorn’s Maximizer™ Collapsible Container is a revolutionary alternative to corrugate. It’s innovative design features easy one-person assembly. Reuse it hundreds of times for shipping and storing light-duty dry goods and then collapse it flat in seconds. Visit the NEW buckhorninc.com for more information, and request a quote today! ©2012 Buckhorn / Myers Industries, Inc. # 050212 US: 1.800.543.4454 Canada: 1.800.461.7579 www.buckhorninc.com BULK BOXES | HAND-HELD CONTAINERS | IBCs | PALLETS | SPECIALTY BOXES mmh.com Modern Mat eria l s Ha ndl ing / J u n e 2012 31 MODERN equipment report even supply of containers, says Knapp’s Schnabl. “One rack line of the [shuttle] performs 800 storage and retrieval movements in one hour and consumes approximately 2 kWh, which corresponds to the energy consumption of two vacuum cleaners.” Multi-benefits of shuttle In addition to being fast and energyefficient, shuttle systems are flexible, explains Dematic’s Ruehrdanz. With the ability to handle totes, trays, bins, cartons, cases and trays, shuttle systems can accommodate different load types in variable sizes and the load handling device can ‘flex’ to multiple load widths. Flexibility is also gauged by the system’s ability to work within the confines of an irregular building space. A traditional mini-load AS/RS doesn’t have the same modular design options because it needs a square form of racking, but the shuttles’ modular rack structures can 32 JU N E be adapted to existing irregular building shapes which optimizes the storage space inside the building’s cube. Because shuttles can go in and out both ends of aisle, the system can be configured to accommodate unusual or irregular facility dimensions. Modular rack can be designed around building components on the ceiling like air conditioning units or designed to bridge floorlevel concerns like lift truck traffic routes. Still, shuttle technology should be treated like another tool in the toolbox. This tool, for example, works well in ambient environments but has not yet been perfected for use in the deep freeze warehouse environment, says Swisslog’s Hayer. This is because the vehicles have electronic components that don’t function well in temperatures that dip below 32 degrees Fahrenheit. Keeping freezer temperatures low is a high operational expense, so you don’t want to introduce anything in the 2 0 1 2 / MO D E R N MATE R IALS HAND L I NG freezer environment to heat up the components that could add to the cost of temperature control. With virtually unlimited design possibilities, Knapp’s Schnabl says, a system can be tailor-made to fit the customer’s requirements today and in the future can be adjusted simply and effectively to meet changes in their market sector. “Shuttle technology will allow integrators to have a bit more flexibility in developing the most cost effective solution for end users,” says Schaefer’s Simpson. Companies mentioned in this article Companies mentioned in this article DEMATIC: dematic.com KNAPP USA: knapp.com SCHAEFER SYSTEMS INTERNATIONAL: ssi-schaefer.us SWISSLOG: swisslog.com TGW SYSTEMS: tgw-group.com Presents a Half-Day Virtual Conference on The State of Materials Handling Automation Thursday, June 28, 2012 • 11:00 a.m. EDT Register now at www.SupplyChainVirtualEvents.com Join Group Editorial Director Michael Levans and Executive Editor Bob Trebilcock of Modern Materials Handling to examine the latest developments in materials handling automation. Our Virtual Conference will bring together recognized experts from the materials handling world and will unveil highlights of Modern’s latest survey on software usage. Attendees at our exclusive Virtual Conference will learn about: • The impact of multi-channel retailing on overall materials handling operations. • Survey results on the evolution of enabling supply chain software and automation. • The rapid rise of AGVs and automatic storage—expected to grow by 12% this year. Sessions Goods-to-Person Order 1 Fulfillment: The MultiChannel Retailing Effect Software: Results of 2 Modern’s 2012 Software Usage Survey Speaker: Norman E. Saenz, Jr., Senior Vice President, Principal, TranSystems Topics will include: • The impact multi-channel retailing is having on materials handling operations; • How goods-to-person solutions are evolving to meet the multi-channel challenge; and • The productivity benefits of goodsto-person solutions. Speaker: John Hill, Director, St. Onge. Topics will include: • The evolution of SCM software inside the four walls; • How warehouse management systems (WMS) and warehouse control systems (WCS) are managing the release and flow of orders; and • A look at the adoption, upgrade and ROI timeline for each of these solutions. Register now at The Rise of 3Automation: AGVs & AS/RS Speaker: Troy Donnelly, Project Director, Peach State Topics will include: • An overview of the latest developments in AGV and AS/RS technology; • How AGVs and AS/RS solutions are being applied; and • Benefits of implementation and future development forecast. www.SupplyChainVirtualEvents.com modern best practices Automotive: Make lineside delivery count 34 mmh.com modern best practices It’s been a rough road for the automotive industry, but production is increasing. To keep pace, auto manufacturers are focusing on lineside delivery strategies that get the right product to the right operator at the right time. By Lorie King Rogers, Associate Editor I n an automotive assembly plant, it’s all about keeping the line moving. In 1913, Ford’s Model T rolled off the assembly line in about 93 minutes. These days, manufacturers are rolling out vehicles at a rate of about a car a minute. To keep pace with these revved up rates, every step of the process must be lean and efficient, including the delivery of parts to the assembly line, or lineside delivery. This means getting the right parts and components to the right operator at the right time with the right equipment. The assembly line work areas are shrinking as companies work to lean down operations. Gone are the days of storing days worth of just-in-case product, today companies are storing hours worth of product and making deliveries just-in-time and just-in-sequence for the next vehicle cruising down the line. But it’s not just when the inventory Shifting away from the line, components can be preassembled in other areas of a manufacturing facility and delivered to the line ready to be installed in the vehicle. mmh.com An automatic guided cart, guided by magnetic tape, moves a customized trailer carrying fascias in an automotive factory. is presented that matters, it’s also the what and how that makes lineside delivery an important part of the manufacturing process. For example, rather than individual parts being delivered to the line, more kits and assemblies are being presented to the operator’s workstation. These kits, often housed in totes, give workers the parts and tools necessary to complete the specific components they are building, while assemblies, like dashboards, are complete units delivered lineside ready for installation. “In the old days there were 6,000 to 7,000 pieces that had to be assembled on the line,” explains Tom Meyers, national sales manager for Muratec. “Now you may have 200 to 300 assemblies that go to the line ready to be incorporated into the car. This has saved the auto industry a lot of money and brought up the quality because you can test the assembly along the way before it’s put into the car.” Different assembly strategies mean different lineside delivery strategies and technologies. Here’s a look the best practices of lineside delivery and how equipment like manual carts, smart carts, automatic guided vehicles, autonomous mobile robots and overhead handling equipment are being implemented. Manually operated carts While the trend in the materials handling sector, including the automotive industry, is toward automation, manual Modern Mat eria l s Ha ndl ing / J u n e 2012 35 Automated Vertical Storage Systems It All Adds Up To VALUE Small parts are expensive. Traditional shelving eats up valuable ßoor space and exposes parts. WhatÕs more, parts can be tough to Þnd and reach; keeping accurate inventories a challenge. The Lauyans Small Parts Storage System (SPSS) is a USA manufactured solution offering high density storage utilizing vertical space for greater footprint capacity, worker safety, security, labor savings and the most competitive pricing available. Before you decide to buy any Automated Storage System, go online and check out our pricing. www.SPSSonline.com It All Adds Up To VALUE Lauyans & Company, Inc. 1-866-LAUYANS (528-9267) modern best practices Manual carts can be outfitted with customized uppers that allow materials to be presented to operators ergonomically. movement can still be a best practice for some operations. “Lean operations have the same goal: Invest less capital and come up with simpler solutions,” explains John Neumann, president of K-Tec. “Carts bring material flow to lean manufacturing, but the challenge to suppliers is to come up with new ways to be effective.” Because end users want customized solutions, there are hundreds of cart design options available. In one example, carts with rotating decks can be individually equipped with stainless steel uppers, like pop-up shelves, to allow more parts to be moved on the cart. The horizontal shelves are stocked with parts and delivered to the workstation in the right sequence. As the operator selects parts from the shelf, the deck can be rotated to allow quick and easy access, without excessive reaching. When the operator has unloaded the top shelf, the shelf springs up into a vertical position so the operator can access the stock on the next shelf. This simple solution works well for a number of reasons. According to Neumann, manual carts make it easy to quickly locate and pick up the right parts ergonomically. Additionally, he says, “The operator on the line doesn’t have to do anything other than the operation, meaning no searching for parts, making decisions about the right tools to use, or unpacking parts and removing packaging materials from the workstation. And, if a big plant wants to change a line, you can move a cart in 10 minutes for free.” While manual carts offer an inexpensive, flexible way to transport parts, there are limitations. To avoid worker injuries, an operation has to apply spe- A fork-free environment Manual carts, AGCs, AGVs, autonomous mobile robots and overhead handling systems all share a few important characteristics—they improve ergonomic handling and they are not lift trucks. Lift trucks working alongside people in a manufacturing facility can raise safety concerns. One way to enhance safety is to create a “fork-free” environment, which means limiting the use lift trucks in areas where there are a lot of people, areas like the assembly line. A fork-free environment opens the door for automated solutions to transport product to the line. “Transportation is considered a low value-added component–necessary, but low. But if you modernize your transportation, you could design a more efficient work cell. In other words, you have to look beyond the work cell in order to improve it,” says Bill Torrens, director of sales and marketing at RMT Robotics. Beyond the work cell, another benefit of using these solutions for lineside delivery is that you can change the dimensions of the aisles. The design of manufacturing facilities was once determined by the materials handling equipment. Today’s advanced technology is not only improving lineside delivery, it is enabling manufacturers to design and build smaller facilities, which presents tremendous savings opportunities. USA Manufactured mmh.com Powered lineside delivery solutions, which are capable of moving loads up to 6,000 pounds, are easy to install, scalable and can be customized to transport virtually any car parts from storage to the line. cific guidelines of gender, height and weight to determine the ergonomics and safety of usage. AGC and AGV spell flexibility Moving from manual to powered lineside delivery solutions, smart carts, or automatic guided carts (AGCs), are capable of moving loads up to 6,000 pounds. Guided by magnetic tape on the floor, they allow users to change the guide path quickly and easily. “AGCs are popular for lineside delivery because they are extremely flexible,” explains Noel Dehne, vice president of automotive for Daifuku Webb. “These systems improve the process by automating it and by providing flexibility that other forms of automation cannot. They are also easy to install and scalable, enabling users to simply add more carts to increase throughput.” In some cases, AGCs, or tugger systems, pull trailers that can be customized to transport kits, pre-assembled components and virtually any car parts from storage to the line. They can also be equipped with customized carriers to move specific parts. By simply changing the customized carrier, different parts can be moved to the assembly line. “One day the AGC can move fascias, but if the company needed to move steering wheels a new carrier could be designed and still be moved by the mmh.com cart,” Dehne explains. AGCs can also be equipped with other devices such as scissor lifts that can raise and lower the load for improved ergonomics when delivering the product to the operator at the workstation. Like AGCs, automatic guided vehicles (AGVs) can also be introduced to the lean manufacturing process without the need for plant modifications and are flexible enough to adapt to an operation’s changing business needs. Batterypowered and computer-controlled, AGVs also have defined paths and are effective solutions for moving materials on repetitive, pre-determined routes. Both AGCs and AGVs can redistribute workers in your plant to valueadded positions, improve safety and material tracking, and reduce labor costs. These automated materials handling systems reduce lift truck traffic, increase plant safety and improve the quality of the build because workers don’t have to walk to the storage area and make selection decisions, explains Neville Croft, executive vice president of Transbotics. When the AGV arrives lineside with its delivery, there’s a handshake of sorts, explains Croft. The exchange of information validates that the AGV has arrived in the right place with the right material and initiates the process and activates controllers, motors, lifts and ... the name to trust! For more than 65 years, RIDG-U-RAK has been the innovative leader in storage rack design and production. Whether you need replacement beams or a storage system covering 30 acres of warehouse space, RIDG-U-RAK is the name to trust. Trust RIDG-U-RAK with your next project • One of the largest rack manufacturers • Capacity in excess of 60,000 tons per year • Project management and installation services • Full array of storage system solutions • Unparalleled innovation, design and application experience Full Line Selection Guide & More Toll Free: 866-479-7225 www.ridgurak.com REG . #5150 Selective Pallet Rack • Drive-In • Push Back Flow • Pick Modules • Cantilever • Stacker Cranes Roll-Out Shelving • Seismic Base Isolation modern best practices other electro-mechanical devices that complete the delivery. Autonomous mobile robots Traditional AGCs and AGVs work well in repetitive applications that move from point A to point B. However, they are not autonomous, meaning they are tethered to their guidance systems and travel on a fixed path. Autonomous mobile robotic solutions, however, can navigate and maneuver around objects—moving or stationary—independently from a random origin to a random destination. This capability is especially important in a manufacturing area where “Imagine the profit you could glean if you build one more car per hour.” —Bill Torrens, director of sales and marketing for RMT Robotics things are moving randomly. Bill Torrens, director of sales and marketing at RMT Robotics, describes the manufacturing environment as “organized chaos” and explains that autonomous mobile robots “have the flexibility to move within that labyrinth. Using a solution that has the flexibility of an autonomous mobile robot, you can change the game.” Torrens explains that you can change the location of a kitting area without creating the challenge of transporting parts to the line. The advantage of dynamic layout means space efficiency and optimized productivity. But don’t think of these robots are a replacement for workers. “Robotic solutions don’t eliminate people, they amplify throughput at a workstation,” Torrens says. “Think of it as the technology lending a helping hand to increase performance, not to replace people. If you could realize a 20% improvement, that would be huge. Imagine the profit 38 Ju n e Carrying materials from the kitting area to the assembly line, mobile robotic solutions are flexible systems that can navigate from random origins to random destinations. you could glean if you build one more car per hour.” Ergonomic enhancements Leading automotive manufacturers are using materials handling equipment to lend a helping hand when it comes to how the parts are delivered to the line and presented to the worker. Delivering parts to workers ergonomically, or in the golden zone, means they don’t have to reach and strain, and can focus more easily on the task at hand so the part goes into vehicle with precision. “Cost savings, process improvement and increased productivity within a plant stem from changes in technology. Automotive manufacturers are always looking for materials handling solutions that improve safety and ergonomics,” explains Michael Paisley, controller of the Dearborn Mid-West Conveyor Company. One example of delivering work to the operator in the golden zone is with an overhead rotational carrier. It holds the suspended car body upright then rotates it 90 degrees, one way or another. Its rotating capability enables the worker to safely access specific areas of car without reaching and bending. “The carrier rotates the car sideways so the worker can look straight at it to work on it,” explains Paisley. Another overhead handling solu- 2 0 1 2 / Mo d e r n Mate r ials Hand l i ng tion is a monorail system. Electric and quiet, some monorails can handle loads of up to 250 pounds, while others can move and handle the entire car. Ergonomically speaking, explains Muratec’s Meyers, “it’s better to drop down to the height needed rather than lift up to the height needed.” M Companies mentioned in this article Companies mentioned in this article Daifuku Webb: daifukuwebb.com Dearborn Mid-West Conveyor Company: dmwcc.com K-Tec: ktecinc.com Muratec: muratec-usa.com RMT Robotics: adamrobot.com Transbotics: transbotics.com mmh.com This label Speaks volumes you talk... we work Voice Pick solutions for a heads-up, hands-free environment Positive feedback...Every time [email protected] | 800.541.8506 x100 | www.idlabel.com WAREHOUSE SIGNS RACK LABELS PREPRINTED LPN LABELS NATIONAL INSTALLATION SERVICES modern productivity solution Workstation bridge crane handles big jobs for small machine shop Fuller Machine Shop’s overhead handling solution enhanced worker safety and ergonomics. By Lorie King Rogers, Associate Editor T he Fuller Machine Shop, located in Newport, N.Y., tools metal parts for customers in a number of industries including aerospace, computer, solar and alternative energy. The company has been independently owned and operated by Rodney Fuller for the past 15 years. As a skilled machinist and businessman, Fuller was growing the business and expanding his customer base. But as that customer base grew and the parts he was running through his lathes and milling machines were becoming larger and more diverse, Fuller had a heavy problem on his hands. “A lot of the parts were small, maybe 65 pounds, but now we’re getting parts that are 12-inches in diameter and weight about 225 pounds,” says Fuller. The challenge was how to handle the larger parts and safely and efficiently load them into the lathe and milling machines. Fuller had been using an engine hoist, but it would take three workers to maneuver the load. 40 Ju n e 2 0 1 2 / Mo d e r n Mate r ials Hand l i ng mmh.com modern productivity solution So Fuller invested in a ceilingmounted, workstation bridge crane with a 500-pound lifting capacity (Gorbel, gorbel.com). The overhead system features an enclosed track that allows the crane to move with very minimal manual effort. “The system has exceeded my expectations,” says Fuller. “What used to take three people 45 minutes is now a one person job that only takes a minute or two. Our productivity has improved significantly.” The bridge crane has also solved the problem of maneuvering the chucks that hold the metal in place while it’s being processed. Moving the chucks, which weigh about 80 pounds each, had required the workers to simultaneously lift and reach out about 18 inches. The bridge crane makes maneuvering easy, which is crucial because Fuller’s is a job shop, meaning everyday is a different job with a different set up. The overhead bridge crane has made handling easier, improved productivity and safeguarded the operation. the coils and that took time,” explains Tom Coward, president of Excelsior. “Then, if you found the one you needed on the bottom of a stack of coils, you had to move the ones on top before you could pull it out and get it into the processing system.” Excelsior installed an automated handling system (Demag Cranes & Components, demag-us.com). The integrated coil storage system includes a top-running double girder crane that can handle 40 metric tons and is equipped with on-board controls for automatic operation and inventory tracking as well as storage strategies. Upon arrival from the customer’s processing mill, coils are assigned a unique identity. Then, using data points like diameter, length and weight, the system models a profile to determine the ideal storage location. The system remembers each storage location for quick retrieval. It moves along the grid and lowers the open coil grab arms to the precise height. When the arm’s photo eye beam hits the receiver on the other arm, it’s safe to close the arms and lift the coil. Then, if only some of the metal on a coil is processed, the system records new data points to determine a new storage location. And, the system is pro- Crane handles lifting of heavy metal Excelsior Steel installed an automated overhead handling system to improve inventory tracking and provide product protection. S ince 1967, Excelsior Steel, headquartered in Toronto, Canada, has been processing heavy metals, like stainless steel, copper and aluminum, for customers in a broad spectrum of industries such as hospital kitchens, railcars and exhaust systems. The company had been using a manual overhead handling crane system to move metal coils that weigh between 15,000 and 20,000 pounds. “In the manual set up, you had to look to find mmh.com Modern Mat eria l s Ha ndl ing / J u n e 2012 41 modern productivity solution grammed to stack coils safely and to avoid product damage. According to Coward, the new system has enabled Excelsior to run faster and more efficiently. Metal coils are still stored three levels high, but now Excelsior knows where inventory is at all times, and customers can access the system online to track their product from arrival through processing. The system provides better customer service, better inventory management, and had freed up Excelsior manpower to do more value-added tasks while the crane does the heavy lifting. Feed Commodities increases storage F eed Commodities is a feed and grain business located in Tacoma, Wash. The company recycles bakery by-products into animal feed for use in the dairy and poultry industries. In early 2009, president Jim Seley found that lack of warehousing space was becoming an issue and needed to act quickly to take advantage of rising opportunities within the industry. “We needed a new building to add warehousing space so that we could introduce a new product to our end users,” Seley says. “We had a tight timeline to do this in, or we would P SERIES 1/4 PAGE 2012_MMH - Advance Lifts 1/30/12 3:43 PM Page 1 THE ADVANCE “P” SERIES ADVANTAGES 4250,000 CyCLe Lift WArrAnty: Our standard warranty exceeds the cycle warranty that many of our competitors’ offer on their high cycle lifts. 41.750” Wide mAin AxLe beArings: Bearing life increases exponentially with increases in width. Our “E” lifts and 90% of our competitors’, lifts only have .75” wide main axle bearings. The “P” series is 233% wider. 4PAtented PLAtform Centering deviCe: Our tests have shown this exclusive feature can double or triple the life of a lift by eliminating steel friction between platforms and legs. 4UL Listed ControLLer AssembLies: Only Advance Lifts has a UL listed panel shop on premises. This insures reliability and safety for our customers. we offer THe MoST LIfe Per $ SPeNT 1-800-843-3625 www.advancelifts.com 42 Ju n e 2 0 1 2 / Mo d e r n Mate r ials Hand l i ng have missed a great opportunity.” Seley began researching online for possible warehouse options and decided to install a 100-foot wide by 100-foot long fabric building and worked closely with the supplier to erect the structure in about 30 days (ClearSpan, clearspan. com). The structure is working well for the company, and Seley says the extra space has more than one advantage. “We are using the space for much more than anticipated. Apparently, if we have covered space, we will use it,” he says. “We converted the parking lot into a building without losing any of the parking lot functions. I can park equipment inside, but if I need the space for something else, I have a great covered space.” The structure’s open interior allows ample space and height for material and equipment, and the natural lighting that filters through the cover is an added benefit. M mmh.com Puzzled over Workstation Productivity and Efficiency? Let Dehnco Help You Evaluate and Integrate Workstations, Supply Storage and Equipment Needs with Your Automation, Technology and Material Handling Systems . . . AT A PRICE YOU CAN AFFORD W. I. S. E. Workstation Integration System Evaluation Dehnco offers a simple 4 step evaluation process that: • Promotes Ergonomics • Creates Efficiency • Increases Productivity STEP : 1 STEP : 2 Evaluating Flow Identifying the Process Defined as the movement of materials/ products into and out of the work area. NEW Detailing the Step-by-Step Sequence of tasks required to complete the specific work being done in the area. STEP : 3 Integrating the Supplies and Equipment Required to Complete a Task into the work area. STEP : 4 Integrate the Work Area Design with the Process to Maximize the Efficiency of the Operation. Your Workstation Solution Partner • Product Literature • Storage Ideas IMPROVED WORKSTATION DESIGN • Components • Easier to • Expanded Website Assemble • Products • New Color Pallet Contact Us: Call: 888•400•9427 www.dehnco.com m SCAN TO SEE NEW COMPONENTS Let Us HELP Y ou Defi • SPACE • ne and R STORAGE esolve These Issues • HANDLI NG / DESIGN • 300 Lageschulte St ERGONOMICS • WORKFLOW • SPACE P.O. Box 866 Barrington, IL 60010 • Ph: 888•400•9427 • Fax: 847•382•1615 special report A spe ci a l suppl e me n t t o m od ern m aterials ha n d lin g By Bridget McCrea, Contributing Editor The market’s top analysts discuss the trends that are pushing mobility deeper into every day use and explain just how far we are from realizing real-time supply chain management, complete with visibility that was once only the stuff of dreams. 44 Ju n e 2 0 1 2 / Mo d e r n Mate r ials Hand l i ng mmh.com Trends shaping mobility I n some cases, traditional logistics and supply chain operations are slowly but surely giving way to more streamlined, mobile processes that rely heavily on wireless devices and applications to operate at peak efficiency levels around the clock and around the world. But, many organizations are still saddled with wires, siloed systems and business partners who don’t communicate with one another. These grim realities are holding many logistics managers back from being able to fully realize the benefits of a truly mobile supply chain—that ultimate, “mobile-centric” Nirvana where shipment visibility becomes second nature. Over the next few pages, we’ll look at the top four mobile trends shaping the supply chain and talk to top analysts about just how far away we are from realizing real-time supply chain management, complete with visibility that was once only the stuff of dreams. mmh.com Modern Mat eria l s Ha ndl ing / J u n e 2012 45 modern special report 1 Cellular technology is advancing rapidly. If there’s a technology that’s helping to get us to realtime visibility in a mobile supply chain, it’s mobile devices and the software that makes them tick. The capabilities of both have progressed significantly over the last decade, with even the most basic cellular phones now including GPS functionality, text messaging capabilities and application functionality. According to Clint Reiser, research analyst with ARC Advisory Group, several technology-agnostic mobile application platforms have been developed to help suppliers extend their enterprise, supply chain and commercial applications to mobile devices. These applications run on handheld cellular devices and offer features such as information capture and retrieval, dispatching, driver and route progress tracking, and location and event reporting. “The performance of the cellular mobility market has progressed much more rapidly than the traditional fleet telematics market—technology that remotely monitors the location, status, health and activity of vehicles and allows for ongoing two-way communications with drivers,” Reiser says. “Cell phone network coverage has become more extensive and the capabilities of mobile devices and mobile software ecosystems have progressed significantly.” As cellular technology progresses it’s also slowly displacing older, legacy methods of moving and tracking freight outside of the four walls of the warehouse and distribution center. Those cellular A s p e c i a l s up p l e m e n t to m ode rn m ate r i a l s ha nd l i ng “In the past, the PepsiCos and Coca-Colas of the world were the only companies that could justify the cost of such solutions.” —Dwight Klappich, research vice president for Gartner advancements have even outpaced customer requirements, making traditional telematics systems obsolete in many cases. “Cellular technology has partially displaced traditional fleet telematics solutions, which generally include in-cab displays, on-board computers, and satellite communications,” says Reiser, who points to improved handheld devices, more robust application software, and cellular network proliferation as the driving forces behind cellular’s prowess. “Future advancements in modern mobility,” says Reiser, “threaten to displace additional segments of this well-established [telematics] market.” 2 Device costs have decreased significantly. Ten years ago, it would have been cost prohibitive for the average company to outfit its managers, employees, and drivers with handheld phones. Cabmounted, onboard computers were even further out of reach, often fetching $5,000 or more per unit. Today, the proposition is much more affordable. The fact that device costs have come down across the board have placed supply chain mobility on the radar screen of more companies, says Dwight Klappich, research vice president for Gartner. He points to the Xata Turnpike fleet optimization device as a good example of how onboard computer capabilities can be achieved with just $30 to $50 a month versus $5,000 per unit. The size of a deck of playing cards, the device is powered by a cable connector and uses Bluetooth to communicate with handheld devices. “In the past, the PepsiCos and Coca-Colas of the world were the only companies that could justify the cost of such solutions,” says Klappich. “The guy with five trucks was left out of the loop. Thanks to reduced device price points that’s no longer the case.” 3 Mobile technology is helping companies gain unprecedented visibility. There’s nothing quite like a little peer pressure to get people to pay attention to advancements in mobile technology. When it comes to the supply chain, visibility gains tend to be the key drivers: When one company achieves them, everyone else wants them, too. “Right now we’re seeing unprecedented visibility across the supply chain made possible by mobile technology,” says 46 Ju n e 2 0 1 2 / Mo d e r n Mate r ials Hand l i ng mmh.com MORE COVERAGE AIRFENCES LAB TESTED SO ROCK SOLID PROVEN GEARBOX DURABLE YOU’LL RETIRE ENGINEERED COMPLETELY SEALED BEFORE IT TOUGH DOES POWERFOIL X2.0 How do you improve the best fan in the world? You upgrade everything from the ceiling down. You boost performance by more than 28%, improve durability and back it all up with a 15-year warranty*. 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All rights reserved. modern special report A s p e c i a l s up p l e m e n t to m ode rn m ate r i a l s ha nd l i ng Drew Nathanson, director of research operations for VDC Research. Extending from the point of manufacture all the way through to the point of sale, that level of visibility certainly puts the control in the hands of the user. “When companies receive actionable intelligence on precise product location in the supply chain,” says Nathanson, “they can leverage that information internally and use it to gain operational efficiencies, streamline their operations, and reduce costs.” 4 The consumer is leading the mobile charge. Most of the mobile advancements taking place in the supply chain right now can be traced back to today’s demanding, hyper-informed consumer. “Customers want to know about everything: product design; delivery times; how to return the product if they don’t like it,” says Tom Wrobleski, vice president for Capgemini Consulting’s supply chain practice. “All of that has to be handled in the background at both the manufacturing and retail levels.” To make that happen, Wrobleski says an increasing number of companies are turning to mobile devices, solutions and applications. Visibility over customer orders is a top concern that most supply chain executives are trying to tackle right “Customers want to know about everything: product design; delivery times; how to return the product if they don’t like it.” —Tom Wrobleski, vice president for Capgemini Consulting’s supply chain practice now, says Wrobleski, who sees cellular devices, mobile applications, GPS locators (for reaching out to the consumer at the point of sale), and the cloud as a few of the most important tools managers will need to achieve data synchronization and sharing. “Companies will have to focus on flexing up and handling the proliferation of data and an increasingly demanding consumer,” says Wrobleski. “Mobile will play a key role in helping them achieve those goals in their supply chain operations.” Bridget McCrea is a Contributing Editor for Modern Materials Handling Is a real-time, mobile supply chain in the works? with these key trends affecting the state of mobility in the supply chain, many managers are left wondering just how close or how far away we are from real-time supply chain management—complete logistics and supply chain visibility made possible by mobility. At least for now there isn’t a direct answer to that question, but some of the industry’s top analysts offered their thoughts on just how far off that Nirvana really is. The fact that the smart phone is now affordable for companies to purchase and distribute to individuals across the supply chain has put managers a few steps closer to mobile-enabled, real-time visibility, says Gartner’s Dwight Klappich. “That affordability opens up the marketplace and allows companies to procure technology at a much lower price point,” he says. But it will take more than just a phone for companies to begin reaping the rewards of complete supply chain visibility. Klappich says com- 48 Ju n e panies will have to develop holistic, mobile strategies that factor in all aspects of their operations—including activities that take place in and out of the warehouse. VDC Research’s Drew Nathanson says that as companies continue to educate themselves and adopt mobile technologies on a piecemeal basis, the picture of real-time supply chain management and visibility is coming into focus. One area where companies need to place more focus, according to Nathanson, is on better supply chain collaboration among business partners, customers and vendors. Without that piece of the puzzle in place, real-time supply chain visibility won’t be achievable. “Companies are going to have to start communicating and collaborating with one another,” says Nathanson, who expects companies to move in that direction over the next 12 months to 24 months. He says he’s already starting to hear about more partnership-type struc- 2 0 1 2 / Mo d e r n Mate r ials Hand l i ng tures in industries like fashion and luxury goods, where companies can “see” all the way through from the point of manufacture to the point of sale. “It’s definitely happening in some sectors,” says Nathanson, “but I still think we’re years away from that ‘amorphous’ supply chain where everybody talks to everybody else.” With mobile technology continuing its evolution and becoming more affordable for companies of all sizes, the mobile, real-time supply chain is sure to surface in some iteration over the next decade. Knowing this, Capgemini’s Tom Wrobleski says the time is right for logistics and supply chain professionals to educate and equip themselves with the tools they need to harness the trend and to accommodate their own demanding, tech-savvy customers—most of whom are already mobile-enabled. “We can’t avoid the mobile supply chain,” says Wrobleski, “and we also can’t get far enough out in front of it.” mmh.com ONE GOOD INVENTORY TURN DESERVES ANOTHER ... AND ANOTHER ... MERITOR LOGISTICS TRANSFORMS YOUR AFTERMARKET INTO A GROWTH MARKET. Introducing Meritor Logistics. We offer a comprehensive suite of logistics and supply-chain management services to help you break into new markets – without breaking your budget. No logistics infrastructure in place? Not concentrating on your aftermarket as a way to increase revenues? Global expansion seem out of reach? Not satisfied with your current third-party logistics supplier? Meritor Logistics has everything you need to maximize your resources, extend your distribution and exceed your business goals. With Meritor Logistics as your partner, you can achieve head-turning results such as increased customer responsiveness, better inventory turns, improved fill rates and more – all to give your operation the edge it takes to stay ahead. For more, call 1-859-817-3913 or visit MeritorLogistics.com. ©2012 Meritor, Inc. www.meritor.com FOCUS ON Dock equipment structurally supported rigid head member. A watertight seal at the top of the vehicle is created with an integrated spring loaded, foam filled, pivoting header component. Fairborn USA, 800-262-1188, www.fairbornusa.com. Light up the loading dock with LED illumination Safety barrier protects open dock doorways Three different models of the DJG-100 dock barricade protect open doorways at loading docks. The barricades come in 8or 10-foot widths and are configured for either electric/hydraulic or manual hand crank operation. The electric/hydraulic unit includes a safety stop that reverses the arm’s direction when contacted. Constructed of heavy-duty welded steel, the device sports a safety yellow finish with black and yellow safety tape for high visibility. Vestil Manufacturing, 800-348-0868, www.vestil.com. Providing additional light at the loading dock, the flex LED Docklite delivers illumination comparable to an incandescent dock light with a 150-watt PAR38 lamp. The LED head offers 84% energy savings over incandescent dock lights with 150watt lamps by only requiring 0.15 amps to operate. With a light source rated for a 50,000-hour average rated life, the lamp and rubber side seals and baffle. Goff’s Enterprises, 800-234-0337, www.goffscurtainwalls.com. Surface-mounted dock lifts offered in 25 different models features compact construction to minimize the chance of impact by overhead doors or fork trucks. The light comes with an installation mounting bracket that is compatible with most dock light mounting hardware and a flexible arm for easy positioning. Allied Solutions, 800-6435424, www.alliedproductsolutions.com. A line of surface-mounted dock lifts has been expanded with 25 new models. The 6000 series of lifts are offered in four capacities—8,000; 10,000; 12,000 and 15,000 pounds—to accommodate heavier fork trucks and loads. Multiple platform sizes may be specified. The lifts feature lowered heights with shorter ramps to ease loading and unloading. Advance Lifts, 800-843-3625, www.advancelifts.com. High-speed, highperformance doors are wind load rated to 45 mph Block inclement weather with dock door header The WeatherGuard 1600 series of dock door headers protects the loading dock area from rain, snow, sleet, hail and wind. Ideal for areas where the drive approach slopes toward the dock opening—causing rain water to funnel into the dock area— the unit enhances employee comfort and prevents cargo damage. The header is offered as a complete package or as a retrofit to existing seals and shelters. To allow natural light into the loading operation, the header features a translucent, 50 Ju n e Custom-made, high-speed G2 high performance doors are ideal for interior and exterior use. Featuring easily replaceable, exchangeable panels offered in vinyl, mesh and clear PVC, sections of the door can be swapped out without downtime or destruction of the door. Wind load rated to 45 miles per hour on a 10- by 12-foot size, the doors automatically reset after an impact or blow out. Unique fiberglass extrusions slide securely into custom extruded aluminum side beams for use with both manual and motorized door operations. The doors also include a reverse safety function, welded seams, 2 0 1 2 / Mo d e r n Mate r ials Hand l i ng mmh.com Replace dock lamps with energy-saving LED bulbs Offered as a replacement to incandescent dock lights, the E-Saver LED lamp saves energy without sacrificing light output. The lamp incorporates LED optics that use 27 watts of power to reduce energy costs by 80%, compared to a traditional 150-watt incandescent bulb. Each lamp has a 50,000-hour lifespan to save on utility, maintenance and replacement costs. Equipped with a PAR38 base, the unit fits most existing dock light housings and provides maximum illumination throughout the truck trailer. Durable construction allows the lamp to withstand impacts, while the LED technology keeps the lamp head cool to the touch. APS Resource, 262518-1000, www.apsresource.com. Hot dip galvanized dock levelers resist rust, Dock door exclusively for use with vertical levelers For use specifically with vertical storing dock levelers, the VertiCool door features a 4-inch thick R-23 insulated panel that mirrors the insulated wall panel for superior thermal protection, and 48-inch panel heights that reduce the number of panel joints by 50% for energy efficiency and easy cleaning. To prevent damage, dual compression side seals are mounted to the door panel while a closed-cell foam interior prevents moisture accumulation. The door also includes a heavy-duty polymer thermal break track that runs the full opening height, UV stabilized exterior painted aluminum skin, dual overlapping header seal and compression loop bottom seals that maintain a consistent seal around all sides. TKO Dock Doors, 877-408-6788, www.tkodoors.com. Automatic door drive-away prevention system corrosion A line of hot dip galvanized levelers features a zinc coating that bonds with the metal beneath to create a barrier that is an extension of the metal itself. The coating extends the unit’s overall lifespan by significantly reducing rust and corrosion. Ideal for use coastal areas, food service industries and chemical/pharmaceutical environments, the leveler withstands extreme weather and stringent, chemical-based cleaning requirements. Beacon Industries, 800-454-7159, www.beacontechnology.com. mmh.com Eliminating the risk of unscheduled truck departures from loading docks, the Salvo brake line interlocking system minimizes the possibility of human error to protect workers from injury and property from damage. The device includes a glad hand lock, control panel, and internal and external traffic lights for visual communication. When a truck arrives, the unit attaches to its emergency brake line, immobilizing it. With the device properly attached, a uniquely coded key is released for use in the control panel. Inserting the key into the control panel turns the traffic light green inside to alert workers that the dock door is now unlocked and it is safe to enter the truck trailer, while a red light outside reminds the driver that the truck is not able to depart. Until the automatic door is closed and locked, the control panel will not release the key. Castell Interlocks, 312-360-1516, www.castell.com. Barrier system guards overhead doors from damage To increase door safety while eliminating expensive impact repairs, the patented overhead door safety guard system provides a highly visible reflective safety barrier. The barrier obstructs the vehicle operator from driving through the opening until the door is completely out of the way. Once the vehicle is in position, the barrier arm automatically raises fully open to allow normal use of the doorway. The device requires no electricity to operate and can be installed in less than an hour. It accommodates door openings measuring 14 x 10 feet or larger. Erich Industries, 800-882-5839, www. docksafety.com. Modern Mat eria l s Ha ndl ing / J u n e 2012 51 FOCUS ON Dock equipment Galvanized construction extends dock lift life Vehicle restraint prevents trailer pull outs Dura-Dock lifts transfer loads quickly and safely to and from any truck bed to any dock height without ramps or inclines. Offered in 5,000- and 6,000-pound capacities, the lifts feature corrosionresistant, galvanized base and legs standard. For higher capacities (up to 20,000 pounds) galvanized construction is optional. The lifts work from grade level to a maximum height of 59 inches can be installed to accommodate any truck parking configuration, including perpendicular or parallel. To prevent standing water in outdoor installations, a drain is located in the lift’s base. Platform sizes range from 6 x 8 feet to 8 x 12 feet. Features include a weatherproof pushbutton NEMA-4X control with 20 feet of coiled cord; a diamond-tread, steel platform with beveled toe-guards painted yellow for safety; and removable steel handrails with mid-rails and 4-inch-high kickplates. The TPR truck positioned vehicle restraint automatically positions itself and secures a trailer’s rear impact guard, reducing the likelihood of a premature trailer pull out. The system includes advanced communications housed within its NEMA 12-rated control panel. Three lights provide a safe and efficient loading dock environment by establishing a clear line of communication between the truck driver and dock attendant. Other features include a gear motor that keeps the hook continuously engaged, restraining force in excess of 30,000 pounds, and a lowprofile, 9-inch carriage with service range of 9 to 27 inches off grade. McGuire, 800-624-8473, www.wbmcguire.com. Southworth, 207-878-0700, www.southworthproducts.com. Prevent energy loss with dock leveler perimeter seal When placed along the sides and rear hinge of a dock leveler, the Energy Guard perimeter seal blocks dirt, debris and insects. The patent-pending seal closes the gaps between the dock leveler and concrete pit walls up to 9 inches above dock level to stop air flow, preventing heat and energy loss. Factoryinstalled on new equipment—or offered as a retrofit to existing equipment—the seal has no mechanical components or springs, and requires no scheduled maintenance. Because it does not use curtains or fabric, the seal permits unrestricted access for pit cleaning and dock leveler inspection. Kelley, 877-558-6960, www.kelleycompany.com. 52 Ju n e 2 0 1 2 / Mo d e r n Mate r ials Hand l i ng mmh.com Truck restraint automatically adjusts to trailer height Prevent falls with gate for loading docks, shipping pits The patented SentryGuard cantilever gate helps prevent falls off loading docks and shipping pits. The gate lifts up and out of the way in seconds, so it doesn’t obstruct floor traffic. Gas-assist struts make lifting the gate effortless. Simple to install, the gate requires a small footprint and six concrete anchor bolts to secure it to the floor. A positive-lock mechanism holds the gate fully opened or closed. To enhance visibility, the gate has a high-gloss, powdercoat epoxy finish and special markings. Sizes for 4- to 24-foot wide openings are offered. Garlock Safety Systems, 763-694-2614, www.railguard.net. To prevent unscheduled trailer departure, trailer creep and tip overs, the Impact rotating hook vehicle restraint secures a trailer at the loading dock. The device engages the rear impact guard with a large rotating hook. The housing automatically adjusts to various truck heights and maintains position with the rear impact guard during loading operations. A direct drive system eliminates clutches, brakes or chains and provides safer constant upward bias hook force. Capable of securing all trucks with 32,000 pounds of restraining force, the device comes in automatic and manual models. It is stored above ground in a low-profile housing. Nordock, 866-885-4276, www. nordockinc.com. Heavy-duty hydraulic pit leveler Capable of accommodating heavier loads, the HDH heavy-duty hydraulic pit leveler offers dynamic capacities up to 80,000 pounds. The leveler uses extra heavy rear angle with gussets to provide maximum structural support and frame strength. Constructed with 55,000pound minimum yield steel, the device’s base frame support struts provide structural reinforcement and safety. For safety, yellow and black diagonal stripes are included on the integral toe guards with yellow full range toe guards. Pioneer Dock Equipment, 800-251-3382, www.pioneerleveler.com. Put a Pencil to Us Trapped key system secures trailers to dock Protecting dock workers by enforcing a safe sequence of actions, the DSS trapped key loading dock safety system is easily installed with minimal disruption. The system does not allow a loading dock door to be opened until the trailer brakes are locked. When air is released from the trailer’s brake line, the mechanical brakes automatically engage. Once the trailer brake glad-hand is set, the glad-hand key is released allowing the loading dock door to be opened. The system keeps the brakes locked until loading/unloading is complete. Usable with all vehicle types, the system can also interlock with other existing dock safety products. Omron Scientific, 800-479-3658, www.sti.com. Reduce your operating costs with wheels that last longer than the competition. Thombert is the most requested brand by warehouse managers nationwide. Guaranteed life and lower costs! Test our polyurethane wheels and tires against your current brand. Calculate your total cost per hour, and if Thombert is not lower, you get your money back. It’s that simple. The Lowest Cost T H O M B E R.comT 800-433-3572 • [email protected] mmh.com Modern Mat eria l s Ha ndl ing / J u n e 2012 53 FOCUS ON Dock equipment Air-powered dock leveler requires no electricity Offered as an alternative to hydraulic, mechanical, low-pressure, high-volume air bag levelers and power-assisted levelers, the CentraAir series powered dock leveler incorporates an automotive grade bellows system. Based on the same technology found in air-ride suspension systems throughout the trucking industry, the system uses existing shop air or a dedicated compressor. It can be run manually by a lanyard control (located at the back of the leveler) or can be push-button operated. Ideal for power-starved or conveyor-loading applications, multiple units can be run off a single air supply. Its low amp draw at each dock (0-0.07 amp) saves costs in comparison to conventional push-button leveler systems. Poweramp, 262-255-1510, www.poweramp.com. Portable steel yard ramp facilitates loading/ unloading High-volume, low-speed dock fan controller The iFAN system networks high-volume, low-speed (HVLS) fans throughout a facility—including those located at the dock—to control them from a centralized location. Up to 30 fans can be managed per configuration. The fans are networked to a 23-inch touchscreen computer that displays custom graphics representing the facility’s exact fan layout. This screen allows administrators to control fans individually, by zone and throughout the entire facility. Variable parameters include time settings, temperature settings or temperature adjustments. Serco, 877-933-4834, www.sercocompany.com. Allowing traffic to move from the dock level down to the ground, or from the ground into the back of a truck, a portable steel yard ramp helps loading/unloading flow smoothly. The ramp includes 18-inch industrial solid rubber pneumatic tires for easy movement of the ramp around the shipping yard. For fast, reliable height adjustment, a hydraulic system is integrated into the unit. Other features include a tow clamp or fork clamp for easy transportation, serrated bar grating on the ramp surface for traction and to prevent debris build up, and a 72-inch long, level-off section for easy access to end loads. Safety chains hold the ramp in place while in use. Systems Inc., 800-643-5424, www.docksystemsinc.com. Hook-style truck restraint Dock seal, shelter options provide weather barrier Three dock seal and shelter options help improve dock efficiency. The Terminator gap seal automatically closes the opening left by trailer swing-out doors to create an effective weather, dust and insect barrier that also saves energy costs and increases security. Installed with fullheight Velcro fasteners, the curtain can be removed when weather conditions require additional ventilation. To extend shelter life, a head curtain includes wear pleats to prevent tearing caused by the corners of the trailer. A safer dock environment is created by a rain shield that automatically seals to a standard-height trailer top to divert water away from the dock seal. Hugger Dock Equipment Company, 800-837-4847, www.huggercfp.com. 54 Ju n e For securing of vehicles at the loading dock, the Lock & Load hook-style truck restraint features a specially engineered gear motor that uses a one-way mechanical disc brake system to keep the hook continuously engaged for added safety. The gear motor uses multiple powertrain components to distribute stress and optimize velocities, maximizing long-term durability. Requiring electrical current only when engaging or disengaging the rotating hook with the trailer’s rear impact guard, the device saves energy. Its slim profile reduces the risk of collision damage unit or to truck trailers. Key switch override is included standard, as are LED communication lights. Nova Technology, 262-502-1592, www.novalocks.com. 2 0 1 2 / Mo d e r n Mate r ials Hand l i ng Mobile yard ramp provides ground-level access to trucks, railcars or buildings Capable of converting any vacant space into a freight-handling center, the portable Copperloy mobile yard ramp is offered. The ramp expands present dock capacity, or creates loading facilities where no dock exists, without new construction. Easily rolled from job to job, the ramp provides ground-level access to trucks, railcars or buildings. To accommodate forklift traffic, the ramp accommodates capacities up to 30,000 pounds. JH Industries, 800-321-4968, www.copperloy.com. mmh.com Product Showcase Pre-engineered palletizing package includes robot A pre-engineered palletizing configuration, the PalletPack 460, provides packaged robotic palletizing components for high-speed, endof-line palletizing. Featuring the IRB 460 palletizing robot, the system offers integrated hardware with full documentation to significantly reduce overall project costs and engineering set-up time. This allows integrators to more easily specify and design palletizing systems. The package can be configured for either high-speed bag palletizing or compact end-of-line case palletizing. It also includes an end-of-arm tool, a PLC, a safety PLC, support software, user documentation and a control pendant with easy-to-use graphical interface. ABB Robotics, 248-391-9000, www.abb.com/robotics. Sloped storage bin inserts Slope-It bin inserts for the supplier’s model 30224, 30230 and 30240 AkroBins improve visibility and accessibility of supplies by keeping them close to the front of the bin. The snug-fitting, 15-degree slope inserts direct parts to the front of the bin without impeding its normal hanging or stacking capabilities. Tight-fitting wiper seals on the insert edges prevent parts from migrating underneath. Ideal for a variety of applications—including industrial, retail, manufacturing, order picking and more—the inserts transform the supplier’s existing bins to a slope-bottom bin in one easy step, and can be removed and reused. To minimize scratches, they feature a textured surface. Akro-Mils, 800-253-2467, www.akro-mils.com. :DUHKRXVH DQG '& PDQDJHUV OLVWHQ WR PH , KDYH RYHU \HDUV RQ WKH MRE« Case packer supports quick, pre-programmed changeovers To run multiple package sizes and pack patterns, the Model 206 case packer quickly switches from a variety of pre-programmed options selectable from the operator console to reduce changeover time. The packer handles multiple styles of cartons, cans, and semi-rigid containers forming them into regular slotted containers, half-slotted containers, half-slotted container display cases or trays. Operators select the new product and case/ tray size from the options and the motorized changeover is activated. For extreme product size changes where change parts are required, modules with locking handles support a no-tools changeover. The unit packs up to 30 cases per minute (depending on the product and pack pattern) and handles cases ranging from 7 x 6 x 5.5 inches to 18 x 16 x 18 inches. A-B-C Packaging, 800-237-5975, www.abcpackaging.com. mmh.com 3RUWDEOH VWDFNLQJ UDFNV IURP 6DYH WLPH« 6DYH PRQH\« 6DYH VSDFH« :H PDQXIDFWXUHFXVWRP GHVLJQ :H EX\ DQG VHOO XVHG UDFNV WLHUUDFNFRP Modern Mat eria l s Ha ndl ing / J u n e 2012 55 Product Showcase Single mobile unit houses battery watering, changing station Industrial fan offers 28% increase in coverage area The Powerfoil X2.0 industrial fan has been upgraded to significantly increase its airflow coverage area over the previous model. Using a system that combines patented airfoils and winglets with patent-pending AirFence technology, the fan’s overall coverage has been increased by 28%. The winglet improves airfoil effectiveness by eliminating turbulence at the tip, while the AirFence captures air that would otherwise slip off the end of the airfoil. Offered in diameter from 8 to 24 feet, the fan is covered by a 15-year warranty. Big Ass Fans, 877-244-3267, www.bigassfans.com. Desktop printers handle light-duty labeling needs Offered as intuitive, flexible and smart solutions for light-duty labeling applications in transportation, manufacturing and warehouse environments, the PC43d and PC43t desktop printers are flexible and user friendly. The printers produce 4-inch direct thermal and 4-inch thermal transfer labels at speeds up to 8 inches per second. Equipped with a universal icon interface or color LCD in 10 languages, the printers provide immediate and intuitive notifications to reduce training and support needs while maximizing uptime. The printers support one-handed media loading and quick configuration via a USB stick device for easy installation and maintenance. Intermec, 800-347-2636, www.intermec.com. 56 Ju n e The Battery Mule is an all-in-one battery changing and watering station in a single, mobile unit. The device allows a depleted battery pack to be easily removed from an electric vehicle, and replaced with a charged pack. For charging, the depleted battery pack is rolled to the nearest 110to 240-volt outlet while the electric vehicle remains is in operation. An optional battery watering refill station conveniently holds a gravity refill container for complete battery maintenance. Pallet jacks are not needed, due to an integrated lift. The station is ideal for recharging stock chasers, burden carriers, tow tractors, personnel carriers, automatic guided vehicles, walkies and forklifts equipped with battery slide-out systems. Wesley International, 800-241-2869, www.batterymule.com. Adhesive-backed floor frames protect bar code labels A line of adhesive-backed floor labels and aluminum frames can be installed without screws, saving installation time. Field-tested and proven to be extremely durable, the labels prevent floor damage from screws and eliminate frequent location and slot painting. The kit includes a 0.125-inch beveled aluminum frame backed with a specially formulated, pressure-sensitive adhesive for peel-and-stick installation. For accurate putaway processes, a bar code label can be placed in the frame—which then protects the label from pallet and traffic abuse. Camcode, 800-627-3917, www.camcode.com. 2 0 1 2 / Mo d e r n Mate r ials Hand l i ng Hygienic plastic pallet protects against bacteria To maximize sanitary materials handling practices, the Sani-Pallet hygienic plastic pallet is formed without sidewall seams, gaps, holes or other potential bacteria traps. Residue cannot pool or collect on any exterior surface, making inspection and cleaning more efficient. Featuring built-in Microban antimicrobial protection, the pallet’s high density polyethylene (HDPE) construction provides an added layer of protection against odor and stain-causing bacteria. An impactresistant, double wall delivers high usefullife-to-cost ratio. Bonar Plastics, 630293-0303, www.bonarplastics.com. Convert static rack to mobile to increase storage capacity A line of mobilized storage systems addresses the industrial storage and space problems faced by manufacturers. The ActivRAC system boosts productivity by allowing a facility to easily convert multiple aisles of static storage racks into a compact, single-moving aisle that easily opens and closes for access. Typically installed on an existing concrete slab without the need for a second concrete pour, or additional structural footings, the system mobilizes any existing industrial storage rack to free up space. It also increases storage capacity up to 100% without adding more square footage, while centralizing storage for better control and organization of raw materials, work-in-process, finished goods, and essential support material. Spacesaver Industrial, 866-767-1888, www.industrial.spacesaver.com. mmh.com Label Holders classified Hoist’s hand chain cover rotates 360 degrees The WP 3000 series walkie pallet truck maneuvers in tight spaces and incorporates brushless AC motor technology for responsive acceleration, smooth direction changes and consistent performance throughout battery discharge. Smooth, consistent braking relies on full-motor function, returning energy to the battery for further efficiency. Heavy-gauge steel is used in the frame and forks, while a 30% improvement in grade clearance at the fork heel reduces wear on the undercarriage. The riser axle is positioned at the highest possible point on the forks, eliminating repairs that occur as a result of constant contact with dock boards, pallets and uneven floors. Crown Equipment, 419-629-2311, www.crown.com. [email protected] Security The best low-cost alternative to building permanent walls. W Durable, maneuverable walkie pallet truck 800.242.3919 www.aignerlabelholder.com NE With a patented hand chain cover that rotates 360 degrees, the Hurricane 360 hoist allows for positioning, pulling and lifting of loads from virtually any angle. Offered in models with capacities from 1,000 pounds to 10 tons, the device may be specified in multiple configurations of lift and headroom to accommodate any application. Features include a Weston-style braking system for positive load control and minimal maintenance through easy disassembly (no special tools required). For safety, a load limiter is included standard for simple, automatic overload protection. All internal gears and pinions are built from heat-treated steel. A powdercoated finish protects against corrosion. Columbus McKinnon, 800-888-0985, www.cmworks.com. To advertise, or for more information please contact: Jennifer Drevline, 847-223-5225, ext. 11, [email protected] Folding Guard’s Saf-T-Fence™ partitions. They deliver security and an unobstructed view of your property – with no change to your lighting or heating systems. Modular system can be easily installed, expanded or relocated in any space. In Stock. Download FREE guide at FoldingGuard.com/ kit Components Forklift Equipment AVAILABLE FOR ACQUISITION forklift EQUIP.company Location: GULF COAST , Annual Sales: $1.5 mil , Profitable Mix: Sales/Service/Refurbishment , Owner: Retirement Contact: Doug Ashby, [email protected] , 832-239-9262 mmh.com MODERN MAT ERIA L S HA NDL ING / J U N E 2012 57 modern 60 Seconds with... Don DeSanctis Title: Founder, SDI Group USA Location: Pacoima, Calif. Experience: Nearly 60 years designing and engineering automated materials handling solutions. Founded SDI Group 35 years ago. Primary Focus: SDI Group consults, designs and integrates distribution centers, with a focus on unit sortation for the apparel industry. Modern: Don, your company is celebrating its 35th anniversary, and you’re celebrating your 80th birthday. Those are major milestones. What led you to the materials handling industry? DeSanctis: Back in 1965, I was hired by Allied Stores, a regional department store chain, to design and build distribution centers. There were a lot of family-owned department stores in the country back then that were expanding from one big store to chains of five, six or seven stores, and they didn’t have a clue how to do distribution. Neither did I, but I built my first DC for Allied in Seattle and then worked for them for another four or five years. In 1977, I opened my own operation in California. My focus was distribution systems for retailers and that evolved into a specialty in soft apparel. Modern: You started out as a consultant, but today SDI Group also manufactures conveyor and sortation equipment. How did you make that transition? DeSanctis: We started providing the hardware in 1980. A year or two later, I was in Europe and saw some of the first garment-on-hanger sorters. We licensed that technology and began building the equipment. After that, we brought in bomb bay sort58 J u n e ers. When we first began implementing those systems, we could sort 200 units on hanger an hour. Today, we can distribute to 1,000 stores at the rate of 10,000 units an hour with two people. We have flat sorters that can do 14,000 units an hour. Those types of technology have really improved productivity in the retail industry. It used to take three to seven days to get an order ready for delivery to a store. Now, it takes about four hours. And, by doing all of this, we’ve seen distribution centers reduce footprints by 50% and 60% in the last 10 or 12 years. Modern: After nearly 60 years in the industry, are there any trends that you’re watching? DeSantis: I’m watching to see what happens in China. A couple of years ago, I was running around Shanghai for one of our manufacturing customers in the apparel industry. They 2 0 1 2 / Mo d e r n Mate r ials Hand l i ng wanted us to set up a distribution center in China where we would prepare orders for delivery right to a store or end customer, rather than bring it to California and then distribute it. We were expecting the big retailers to follow suit. For some reason, that never happened. It seems the thinking now is that it still makes more sense to bring the product through customs in the U.S. However, I’m waiting to see if that changes. Modern: Do you have any plans to retire? DeSanctis: I retired once. Two years ago, the president of the company asked me to help set up an infrastructure in South America. It’s an enormous market. If I were 45 or 50 years old, I’d move there in two minutes. Right now, I spend about 90 days a year down there, and I expect to do that for another two years. Ask me then, and I’ll tell you if I want to keep at it. M mmh.com Critical Industry News at Your Fingertips! Modern Materials Logistics Management Supply Chain Management CRITICAL TOPICS Critical Topic areas help you develop strategies and expand your knowledge. Each topic provides you with the news, information, and resources you need — each day. • Automation Modern Materials Logistics Management Supply Chain Management • Conveyors & Sorters • Inventory & Picking • Loading Dock Equipment • Mobile & Wireless • Shipping Pallets • Storage Systems • Containers & Totes • Energy & Sustainability • Lift Truck & Fork Lift • Handling & Warehouse Ergonomics • Packaging • Software & Technology www.mmh.com/criticaltopics New Hornet Horizontal Carousel Order Picking System Lowest Cost, Highest Value Automated Solution Available! New state-of-the-art Horizontal Carousel system designed for flexibility, durability and efficiency. Free Intelligent Machine Health Monitoring (IMHM) system to remotely monitor the health of the Carousels 24/7 to help eliminate potential problems before they impact performance. Just A Few System Benefits: • 12 Month Or Under ROI • Fast & Easy Implementation • Pick Up To 550 Lines/Hour Per Operator • Save Up To 65% Of Your Floor Space • Increase Accuracy To 99.99%+ • Flexibility To Change As Your Business Changes • Extend Order Cut Off Times Looking to Update Your Existing Carousel System? Plug and Play SSC controller provides a fast and economical means to upgrade old Horizontal Carousel systems for pennies on the dollar. Improves reliability and performance WITHOUT COSTLY (gear box & motor) hardware changes and upgrades. AC or DC compatible. Call or Email Today for a FREE Space, Productivity & ROI Analysis S A P I E N T A U T O M A T I O N The Intelligent Material Handling Company 888-451-9711 | www.GetSapient.com | [email protected]