Lift trucks contain the chaos
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® mmh.com PRODUCTIVITY SOLUTIONS FOR DISTRIBUTION, WAREHOUSING AND MANUFACTURING August 2011 The Container Store: Lift trucks contain the chaos 20 Mike Coronado, distribution director, The Container Store THE LIFT TRUCK ISSUE SPECIAL REPORT Top 20 lift truck suppliers 31 EQUIPMENT 101 SERIES: LIFT TRUCKS Lift truck basics 39 INFORMATION MANAGEMENT 15 ways the lift truck is evolving 44
Transcript of Lift trucks contain the chaos
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m m h . c o m
PRODUCTIVITY SOLUTIONS FOR DISTRIBUTION, WAREHOUSING AND MANUFACTURING
August 2011
The Container Store: Lift trucks contain the chaos 20
Mike Coronado, distribution director,The Container Store
THE LIFT TRUCK ISSUESPECIAL REPORT
Top 20 lift truck suppliers 31EQUIPMENT 101 SERIES: LIFT TRUCKS
Lift truck basics 39 INFORMATION MANAGEMENT
15 ways the lift truck is evolving 44
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STABILITY INAN UNSTABLE WORLD.
Who knows what lies around that corner up ahead? Whatever it is, you’ve got 30 dedicated engineers, no fewer than 126 patents and 14 years of proven stability on your side. That’s Toyota’s industry exclusive SAS™ technology. The world’s first, and only, active stability system that dynamically helps protect the driver as it
maximizes productivity. A system so incredibly effective, it can save lives by reducing the likelihood of tipovers and catastrophic accidents. And most recently, led to Peerless Research’s recognition of Toyota as the safest manufacturer of lift trucks in the business. It’s one tough world out there as we all know. But if anything can tame it, it’s Toyota’s SAS. Do yourself, your loads and your drivers a favor and check it out at toyotaforklift.com.
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“this is another terrific transaction for our scanning and mobility business,” said Honeywell automation and control Solutions president and ceo roger Fradin. “eMS strengthens our core mobile computing business and expands our addressable market with complementary new products, channel partners and entry into the warehousing and port segments that we believe will be growth drivers for the business. this also represents an opportunity to demonstrate our proven acquisition integration process.”
mmh.com Modern Materials Handling / A u g u s t 2 0 1 1 3
CeMa: Conveyor index slips 21% in May, remains up from last year
UP FRONT B r e a k i n g n e w s y o u s h o u l d k n o w
tHe conveyor equipment Manufacturers association (ceMa) reported that its May 2011 Booked orders Index was 173. Index in May is down 46 points or 21% from april 2011’s Index of 219 (1990=100). the May 2011 Index repre-sents an increase of 32% from the May 2010 Index of 131.
ceMa’s baseline calculation uses the year 1990 as a comparison. numbers to the right of the equation show the current state of the con-veyor industry as compared to 1990. Figures above 100 indicate growth; while anything less indicates a contraction in the industry.
Honeywell to acquire eMs technologies
a Slowdown In ManuFacturIng growtH appears to be intact based on the most recent edi-tion of the Institute for Supply Management’s (ISM) Manufacturing report on Business.
In its July report, the ISM reported that the index it uses to measure the manufacturing sector—known as the PMI—was 50.9%. this represents a 4.4% drop from June’s 55.3%, and June was up 1.8% from May. according to the ISM, any reading 50 or higher is a sign of economic growth. But even with sequential declines in two of the last three months, July marks the 24th consecutive month economic activity in the manufacturing sector has expanded, with the overall economy showing growth for the 26th straight month.
isM July manufacturing report down from June; still showing growth
tHe InternatIonal warehouse logistics association (Iwla) has created the first metric-driven, facility-output-based sustainable logistics program for warehouse operations in north america, called the Sustainable logistics Initiative (SlI).
Program participants will report and engage in a rigorous and objective measurement process. continuous improvement is bench-marked, and the entire process is verified by an outside independent organization, the Sustainable Supply chain Foundation.
“Many Iwla members have
already adopted the practices needed to dem-onstrate their continuous improvement process in supply chain sustainability, and others will learn quick-ly how to become part of the program through participation in SlI,” said Iwla chairman linda c. Hothem, who is the ceo of Pacific american group and senior advisor to Matson global distribution Services. “the data col-lected through SlI will inform our industry and our customers on the
best and most efficient means to improve sustainable warehouse-logistics practices.”
iWla announces the sustainable logistics initiative
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mmh.com MODERN MATERIALS HANDLING / A U G U S T 2 0 1 1 5
PRODUCTIVITY SOLUTIONS FOR DISTRIBUTION, WAREHOUSING AND MANUFACTURING
VOL. 66, NO. 8
DEPARTMENTS & COLUMNS 3/ Upfront
7/ This month in Modern
16/ Lift Truck News
18/ Lift Truck Tips: Alternative power
50/ Supplement: Warehouses & DCs
58/ Focus On: Packaging equipment
67/ 60 seconds with...
NEWS 9/ Montwieler retires after 28 years as
head of ITA
10/ Robotics orders jump 41% in first half of 2011
11/ Beumer offers Crisplant sortation systems in North America
12/ Plug Power to provide Kroger with GenDrive fuel cells
12/ Coca-Cola bottler installs Crown fuel cell-powered forklifts
13/ Toyota receives National Safety Council Award
13/ INRO deploys forklift of the future
14/ ITA names Feehan next executive director
COVER STORYSYSTEM REPORT
00 HeadlineText
00 HeadlineText
FEATURESSPECIAL REPORT
00 HeadlineText
EQUIPMENT REPORT
00 HeadlineText
INFORMATION MANAGEMENT
00 HeadlineText
PRODUCTIVITY SOLUTION
00 HeadlineText
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-qualifi ed 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 offi ces. 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 permis-sion of the publisher is prohibited. All rights reserved. © 2011 Peerless Media, LLC.
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Caption
PRODUCTIVITY SOLUTIONS FOR DISTRIBUTION, WAREHOUSING AND MANUFACTURING
COVER STORYSYSTEM REPORT
20 The Container Store: Lift trucks contain the chaos The retailer’s lift truck distributor played a key role in optimizing a new DC and securing a 30% improvement in process time.
28 Getting organized; improving productivityA close attention to layout, design and equipment selection makes the most of conventional materials handling processes in The Container Store’s DC.
FEATURESSPECIAL REPORT
31 Top 20 lift truck suppliersWith sales on the rise for the second consecutive year, the worldwide industrial lift truck market is revved up.
EQUIPMENT REPORT
39 Lift truck basicsLift trucks have come a long way since their introduction in the materi-als handling arena in the 1920s. Today, they are smarter and stronger, and still the indispensable workhorses in our warehouses and DCs.
INFORMATION MANAGEMENT
44 15 ways the lift truck is evolvingToday’s lift trucks offer more in the way of technology, power and performance than ever before. Here’s a look at the latest innovations available in today’s trucks.
PRODUCTIVITY SOLUTIONS
48 Slow picking and errors are just a memoryA crafty slotting solution helps Creative Memories achieve more than 99.9% shipping accuracy and improve picking speed.
49 Slotting reaps a bumper crop of benefitsWarehouse management solution uses several slotting principles to control accuracy, production and overall pallet quality.
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-qualifi ed 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 mail-ing offi ces. 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 permis-sion of the publisher is prohibited. All rights reserved. © 2011 Peerless Media, LLC.
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PHOTO: ED LALLO
Mike Coronado, distribution director at The Container Store, worked with fl oor associates to select the new equipment for the DC.
SPECIAL LIFT TRUCK ISSUE
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THIS MONTH IN MODERN
We break the Modern mold a bit this month by focusing this issue fi rmly on one piece of equip-
ment—the tried and true backbone of the materials handling industry, the lift truck.
Why put all of our proverbial eggs in one basket? Well, as our reader research has revealed over the past three years, the recession has forced many fl eet manag-ers to park a large portion of their existing fl eets while they’ve pushed their remaining active trucks to their very functional lim-its—and beyond. In most cases, that fl eet of sidelined trucks is being converted into simple spare parts, scavenged for bits and pieces to keep the worn and battered fl eet hobbling along.
While we understand the realities behind these recent fl eet management practices, we also realize that it’s been a while since many Modern readers have taken the time to survey just how far truck suppliers have come in terms of technology, power and performance. And if you’re about to fi nally retire that tattered fl eet, it’s best to have a full understanding of the options that have recently hit the market.
Enter Modern’s Lift Truck Issue, our comprehensive look at the current state of the market, from the “new basics” of truck design, to the application of existing truck technologies on the fl oor, to a look at where suppliers are headed with future truck development.
To gain the full breadth of our coverage, I suggest that you digest this issue in a pre-determined order. I’d start with associ-ate editor Lorie Rogers’ terrifi c overview of the tried and true “basics” of lift truck
design and application (page 39). It’s been a while since many fl eet managers have brushed up on these fundamentals, and Rogers’ piece is a great re-introduction to counterbalanced, narrow-aisle and low-lift pallet truck functionality.
I’d then swing back to page 31 to get a feel for where the top suppliers stand in terms of revenue and market penetration. And while those top suppliers are on your mind, I’d spend some time with executive editor Bob Trebilcock’s System Report on The Container Store (page 20) to see just how far the supplier/distributor/user relation-ship has evolved over the past few years.
In this case, the retailer’s lift truck distrib-utor played a signifi cant part in optimizing a new distribution center through new racking layout and slotting improvements on top of its standard truck maintenance program as-sistance. In turn, the enhanced relationship helped The Container Store realize a 30% improvement in process time.
And, if you’re eager to peer inside the crystal ball to see where lift truck innova-tion is heading, I strongly suggest you wrap up with Trebilcock’s outstanding “15 ways the lift truck is evolving” (page 44). From ergonomics, RFID integration, advanced automation and robotic functionally, to the development of the lithium ion battery, Trebilcock surveys the leading suppliers on how the trucks of tomorrow will operate, look and feel.
So, if it’s been a while since you caught up on lift truck development and innova-tion, we got your covered. This celebra-tion of the backbone of materials handling should bring you up to speed in short time.
Celebrating the backbone of materials handling
Lift Truck Issue:
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Other Voices | Guest Blog ForumHow to submit a column:www.mmh.com/article/how_to_submit_a_column_to_other_voices
Di@blogbest of Modern’s blogs
BY JOSH BOND, CONTRIBUTING EDITOR
LIFT TRUCKS
Montwieler retires after 28 years as head of ITALONGTIME DIRECTOR TO BE SUCCEEDED BY PERC’S BRIAN FEEHAN
NOT LONG AFTER Bill Montwieler was named executive director of the Industrial Truck Association (ITA) in 1983, he faced a major challenge that sent him on a 10-year journey to reform international lift truck sales practices.
Leaders in the industry became aware that some Japanese lift truck manufacturers—nearly all of them members of ITA—were allegedly dump-ing product into the North American market. Members began negotiating a voluntary restraint program, but despite frank discussions, the measure initially failed at ITA, and it took years for a resolution to create better market conditions for all members.
“What started out to be a real threat to the existence of ITA turned out to be a real growth opportunity for everyone,” said Montwieler in an interview with Modern. “I think at that time, the value of the associa-tion was proven.”
That was the fi rst of many mile-stones that ITA achieved during the last three decades under Montwiel-er’s leadership. Others include the enactment of safety training regula-tions by the Occupational Safety and
Health Administration, which was fol-lowed by compliance offi cer training seminars taught by industry experts; the establishment of a worldwide statistics program; and the recent development of International Stan-dard Organization forklift standards designed to be readily adopted by nearly every country.
Now, after 28 years at the helm, Montwieler is preparing to retire at the end of the year. He will be suc-ceeded by Brian Feehan (see p. 14), vice president of the Propane Educa-tion and Research Council.
Montwieler credits his dedicated staff for some of his successes. One of Montwieler’s fi rst staff moves as head of ITA was hiring Chris Buddenhagen to manage the association’s statistical database. She has been “the heart and soul of the statistics program” and because of her work, ITA now provides comprehensive and very specifi c data on every lift truck sold in the United States, Canada or Mexico, Montwieler said.
While statistics were always impor-tant to the association, “over the last 15 years, Chris Merther’s expertise in standards development has made
ITA’s engineering program just as important” to members, Montwieler said. And, long-term member of the ITA Washington, D.C., staff is Deb-bie Stergar, fi nancial manager and meeting planner. “Debbie is our backbone,” said Montwieler, “and handles all the association’s adminis-trative, fi nancial and meeting duties.”
When he was hired in 1983—es-tablishing ITA as an independently run trade association for the fi rst time—Montwieler said he thought he’d be on the job for fi ve or seven years. “After 28 years, the intellectual challenge is still there, and the job is as exciting as ever,” he told Modern. “But it’s time to move on to other life challenges and to bring new leadership to ITA. With his experience as head of a propane association in Paris for fi ve years, Brian will prove to be excellent in the role of
Bill Montwieler
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industry spokesman.”Retirement plans? Montwieler says
he has many delayed repair and im-provement projects to work on at the 100-year-old house he shares with his wife, Nancy. “I’ll be taking on all the tasks my father taught me—wallpa-
pering, plastering, painting,” he said with a smile. An enthusiastic amateur chef and historian, he also plans to volunteer at an area soup kitchen, to pursue his study of World War I, and to spend more time as Grandpa Bill with his four grandchildren.
AUTOMATION
Robotics orders jump 41% in first half of 2011FUELED BY ITS BEST quarter in six years, the North American robotics industry jumped 41% in the fi rst half of 2011, according to new statistics released by Robotic Industries Asso-ciation (RIA), an industry trade group.
A total of 8,879 robots valued at $577.8 million were ordered by North American companies in the fi rst six months of the year. When orders from outside North America are added, the totals are 10,476 robots valued at $667.9 million. “This was the best fi rst half for our indus-try since 2007,” said Jeff Burnstein, president of RIA.
The second quarter was particu-larly strong, posting gains of 50% in units and 55% in dollars over the same period in 2010.
Burnstein attributed the majority of growth to increased orders from automotive manufacturers and their suppliers, traditionally the largest customer for robotics. “With the re-vitalization of the auto industry in the United States, robot orders to these customers rose 60% in the fi rst half of the year,” he said.
Non-automotive orders increased 23% through June, led by gains in metalworking (up 70%).
Burnstein said some non-auto-motive customers who were slow to purchase robots in the fi rst quarter accelerated their buying in the sec-ond quarter of the year.
“Food and consumer goods customers placed orders for 60% more robots in the second quarter of 2011 than in the fi rst, hopefully a sign of strong growth going forward in this sector,” he said. “The North American robotics industry is on pace for its best year since 2005 in terms of new order volumes, but this could be threatened if there is an economic downturn caused by the lack of an
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agreement in Washington on raising the debt ceiling.”
Burnstein did cite one recent positive development from Washing-ton, the creation of a $500 million Advanced Manufacturing Partner-ship that includes $70 million for a National Robotics Initiative.
“This could have a very posi-tive long-term effect in keeping the United States a leader in robotics, both inside the factory and in a wide-range of non-industrial robotics sectors,” he said.
RIA estimates that some 205,000 robots are now used in the United States. More than one million indus-trial robots are used worldwide.
PACKAGING
Beumer offers Crisplant sortation systems in NACRISPLANT BRAND LOOP sortation technologies, systems and life-cycle support services are back in North America under the Beumer Group, one of the largest designers, manu-facturers, providers, and marketers of automated high-speed loop sortation systems and services.
A member of Beumer Group, Crisplant is a leading provider of sorta-tion solutions worldwide. Crisplant provides solutions and lifetime support for airports, postal facilities, parcel distribution and warehouse and distri-bution centers. Crisplant has led and delivered projects that include many of the world’s largest and most advanced materials handling operations.
Beginning on July 4, 2011, customers in North America once again can refer to original Crisplant customer support, parts, with local inventory for fast fulfi llment. Original life-cycle support, including hotline service, preventive maintenance pro-grams, controls and software optimi-zation packages, and modernization road maps tailored to the unique
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At ProMat 2011 earlier this year, Tony Barr, vice president of market-ing and business development for Beumer Corp., told Modern that customers of Beumer and Crisplant
alike can expect a sea change in ser-vices from both companies. Among Beumer’s sortation offerings is a redesigned crossbelt that uses fewer drives per a given length of belt. The power draw of each driver is 75% less, and crossbelt systems can sort 4,000
to 45,000 units per hour, he said.“We’re taking a disciplined ap-
proach to product development and making sure sustainability is a key strategic fi lter when looking at new innovations,” he said. “2011 appears to be on track for signifi cant growth, both for Beumer and the industry.”
In 1944, Crisplant was founded in Denmark by Svend Christensen. Over the years, the company developed many sortation solutions. In 2000, Crisplant was acquired by FKI, which later changed its name to FKI Lo-gistex. In 2009, when FKI Logistex was purchased by Intelligrated, Crisplant gained independence and reverted from FKI Logistex to the Crisplant com-pany name. Later that year, Crisplant became part of the Beumer Group.
FUEL CELLS
Plug Power to provide Kroger with GenDrive fuel cellsPLUG POWER, a leader in provid-ing clean, reliable energy solutions, announced it has added Kroger to its growing list of GenDrive customers. Plug Power will supply 161 GenDrive fuel cells to Kroger’s food distribu-tion center in Compton, Calif. The order includes four Class 1 units for sit down counterbalanced trucks, 42 Class 2 units for reach trucks and 115 Class 3 units for pallet trucks.
With this partnership, Kroger will power its fl eet of electric lift trucks with GenDrive fuel cells. Because GenDrive is fueled with hydrogen, the only byproducts created through the electrochemical energy-conver-sion process are heat and water.
Coca-Cola bottler installs Crown fuel cell-powered forklifts
CROWN EQUIPMENT announced that a fl eet of 35 Crown FC 4500 series counterbalanced, fuel cell-powered forklifts were delivered to Coca-Cola Bottling Co. Consolidat-
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ed, the nation’s largest independent bottler for Coca-Cola. The trucks were installed at the company’s Char-lotte, N.C., production center.
The Crown FC 4500 series is designed to meet the demands of heavy-duty applications, such as high-volume warehouse environ-ments. The fuel cell model of the FC 4500 maintains the same features and benefi ts presented by the stan-dard model. It is one of more than 20 models Crown has qualifi ed to op-erate with various fuel cells as part of its fuel cell qualifi cation program.
SAFETY
Toyota receives National Safety Council AwardTOYOTA MATERIAL HANDLING, U.S.A. (TMHU) announced that Toyota Industrial Equipment Mfg. (TIEM) was awarded the Occupation-al Excellence Achievement Award by the National Safety Council.
The Occupational Excellence Achievement Award is given to com-panies that have a lost-time injury rate of less than 50% of companies in the same business classifi cation. The National Safety Council tracks data in accordance with the federal OSHA calendar year standard. During the last calendar year, TIEM achieved a lost-time incident rate less than 7% of the average rate in the same busi-ness classifi cation.
“Every associate, manager and executive at TIEM has safety as their top priority,” said TIEM’s environ-mental, health and safety manager Dixon Churchill. “When associates know their managers truly care for their health and safety, it creates an environment where everyone is focused on reaching the company’s business goals. With TIEM’s focus on safety, we see reduced absenteeism, lower turnover rates, higher produc-tivity and better quality products.”
INRO HAS SUCCESSFULLY commis-sioned the world’s fi rst automated standard reach truck for a commer-cial warehouse. A Linde RX17 reach truck has been commissioned as the
fi rst phase of a potential seven-ve-hicle deployment at a central North Island, New Zealand, site owned and operated by global dairy giant, Fon-terra Co-Operative Group Ltd.
AUTOMATION
INRO deploys forklift of the future
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A patented system of camera and laser technologies called “Forkward-Sensing” allows the trucks to interface with a satellite tracking system and perform pick and put-away tasks with pallets of butter and cheese at heights of more than 10 meters. A fl eet of unmanned vehicles is ca-pable of handling 2,000 pallet movements per day across 400 SKUs in the cool-store distribution center, where temperatures fl uctuate between 4°C and -10°C.
“Warehouses are becoming increasingly automated and forklifts are no exception,” said Mark Templeton, CEO of INRO. “So far our customers have had to choose between retaining manually operated forklifts or imple-menting automatic guided vehicles (AGVs) which lack fl exibility. The technologies we have developed create a third option—a fully automated forklift that can be driven when necessary. This has created the opportunity for forklift OEMs to make forked AGVs redundant.”
ITA names Feehan next executive directorThe Executive Committee of the Industrial Truck Association (ITA) recently announced the new execu-tive director of the association will be Brian Feehan, vice president of the Propane Education & Research Council (PERC). Feehan is set to take the reins on Jan. 1, 2012, when Bill Montwieler, who had been executive director since 1983, retires.
“Brian is well known to all of us through his work at the Propane Education and Research Council,” ITA president Jeff Rufener said. “He’s attended every ITA meeting for the last six years, including the associa-tion’s Executive Committee sessions and has contrib-uted mightily to our air quality efforts; Brian joined the ITSDF Board of Trustees last February. His previous experience with the World Liquefi ed Petroleum Gas As-sociation in Paris places him in good stead to continue our efforts in Europe, Japan and China.”
In his role with PERC, Feehan helps the industry-funded organization, focus on engine fuel, research and development, safety and training, agricultural markets, and residential and commercial markets. Prior to his role at PERC, he served as the executive director of the Propane Vehicle Council (PVC). The PVC was the na-tional organization representing the propane industry’s engine fuel interests.
Prior to joining the PVC, Feehan served as the proj-ects director for the World LP Gas Association (WLPGA) in Paris. He holds a bachelor’s degree in political sci-ence and a master’s degree in public administration from George Mason University.
Brian Feehan
MMH1108_News.indd 14 8/10/11 11:00 AM
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16 A u g u s t 2 0 1 1 / Modern Materials Handling mmh.com
Rush Tracking Systems, a provider of advanced tracking solutions, software and services for manufacturing and warehouse
operations, and Sky-Trax, a provider of patented real-time location systems (RTLS) for tracking goods, vehicles and guiding autonomous vehi-cles, have merged to form a single company.
Rush Tracking and Sky-Trax officials said the objective of the deal was to form a vertically in-tegrated provider of smart truck tracking systems for manufacturing and warehousing environ-ments. The deal was made official on July 8.
The companies will continue to maintain their individual names and sell products and services under their own brands. The companies added that they expect “rapid growth” through direct sales to top customers, coupled with growth from a global network of value-added resellers and suppliers.
Rush Tracking Systems director of marketing Paige O’Brien told Modern that the impetus for this deal was to “accelerate growth and solidify leadership in the Smart Truck Solution space.”
And Sarah Brisbin, vice president of marketing at Sky-Trax, said there was not a specific “need” for this deal, as much as an opportunity to bring two talented companies together, adding that this deal had been in the works for less than six months.
When asked what the biggest takeaways of this deal are for customers of both companies, she explained that the merged entities offer up a larger team with a full suite of Smart Truck solutions with financing to accelerate growth both domestically and internationally.
“The biggest improvements will be in the variety of solutions we offer for optimizing safety, asset utilization, labor productivity and inventory accuracy as well as im-proved support, services and accessibility to resources,” said Sky-Trax’ Brisbin. “With the data and business intel-ligence tools we offer, our customers gain the ability to
implement improvements to their operations to improve accountability, productivity and accuracy.”
Officials from both companies said that this new com-pany delivers a comprehensive suite of patented smart truck tracking solutions that optimize personnel safety, asset utilization, labor productivity and inventory accuracy within manufacturing and warehouse operations. And by automatically collecting real-time lift truck load and location visibility data, they explained that customers are able to reduce or eliminate the inaccuracies associated with driver input of data, adding that the resulting busi-ness intelligence data also allows customers to gain the insights needed to implement immediate improvements in accountability, safety and productivity.
What’s more, they also said these solutions automati-cally identify the load on the front of a lift truck by lever-aging either bar code, RFID or optical data collection technologies and then track the position of the materials handling device with Sky-Trax’s optical indoor positioning system.
Sky-Trax, Rush Tracking Systems announce merger
lift truck NEWS
By Jeff Berman, Group News Editor
The merger forms a vertically integrated provider of smart truck tracking systems.
MMH1108_LiftTruckNews_Tips.indd 16 8/10/11 11:22 AM
Mitsubishi goes mobile
Mitsubishi Forklift Trucks announced the launch of its new mobile Web site,
m.mit-lift.com, making it easier for customers to access forklift product information and connect with local dealers while on the go through their mobile devices. The new site includes Mitsubishi product information, a local dealer search function, and easy access to finance information and promotions.
The Web site allows users to view forklift specifi cations and includes the option to request a quote, email a product brochure or download the digital brochure directly from a mobile device. The dealer locator feature gives customers quick and easy access to dealership addresses and phone numbers and includes geo-tracking capabilities for some mobile devices.
“We’re pleased to introduce the new Mitsubishi Forklift Trucks mobile Web site,” said Jeff Rufener, vice president of marketing at Mitsubishi Forklift Trucks. “More and more peo-ple are on the go these days, and the mobile Web site will make searching for a new forklift or fi nding a local dealer even easier than before.”
Crown wins industrial design award
The Industrial Designers Society of America (IDSA) has ranked Crown Equipment again as
one of the world’s best industrial designers. Crown was recently hon-ored with a 2011 Gold International Design Excellence Award (IDEA) for the Crown WT 3000 series of pallet trucks.
Crown has won more IDEAs in the Commercial and Industrial Equipment category in the last 11 years than any other company. This is the 6th con-secutive and 19th overall IDEA award for Crown.
The Crown WT 3000 series of pallet trucks, which is available in Europe, is designed to accommodate intense pal-let truck conditions and high through-put demands. The Crown WT 3000 series combines engineering, durability, performance and operator comfort, and is loaded with innovative features such as the Crown Access 1 2 3, AC technology, and e-GEN braking system to lower operating costs and improve energy effi ciency. The FlexRide suspen-sion system provides riding comfort during trailer loading and transport, and the optional weight-adjustable FlexRide platform reduces impact shock to the driver.
According to Clive Roux, IDSA’s CEO, “The IDEA program is consid-ered by many as the ‘Oscars’ of de-sign competitions because the judg-ing process is rigorous and judged by the experts in their fi eld.”
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MMH1108_LiftTruckNews_Tips.indd 17 8/10/11 11:22 AM
lift truck TIPS
As hydrogen fuel cell technology continues to gain attention and market share in lift truck applications, the emerging con-
tender in materials handling may have hit the tip-ping point, according to experts at Ballard Power Systems. After partnering with Plug Power to de-velop the GenDrive fuel cell system, Ballard has helped put more than 1,200 fuel cell units into service. According to Gary Schubak, marketing manager for materials handling at Ballard, those units have logged more than 2.5 million hours in North American lift truck applications.
“We’re starting to get some market traction, but it’s still a relatively new concept,” says Schubak. “We’re just nib-bling at the heels of the total lift truck market, but we’re to the place where customers use it, like it, and want more of it.”
Ballard began fuel cell trials in 2006, but only in the last 24 months has the technology taken off, says Schubak. Hydrogen fuel cells are still primarily suited for a specific section of the market, says Schubak. He adds that high-throughput, multi-shift fleets of more than 30 trucks will stand to benefit the most from deploying a hydrogen infrastructure.
“For those customers, it might be a less expensive and cleaner way to move,” he says. By replacing battery and fuel tank swap-outs with high-speed, on-demand refuel-ing, the technology can help increase uptime and produc-tivity by streamlining some of the labor-intensive needs of other power sources, says Schubak.
But even as educated users come to fuel cell providers with an understanding of the technology’s viability, some misconceptions remain, he says.
“The big myth is that the only way to get an envi-ronmentally sustainable solution is to spend premium money,” he says. “The truth is that we can show economic
benefit in addition to less environmental impact. You can have it both ways.”
In addition, the initial outlay for fuel cell conversion at a facility could have additional benefits down the road. Commercial fuel cell solutions exist now for most major lift truck classifications, but Schubak says the diesel engine is also in the crosshairs of fuel cell manufacturers.
“Once hydrogen infrastructure is rolled out more widely, customers will want to make use of that,” says Schubak. “We see those opportunities, and we intend to pursue them. You can imagine a day when we’re addressing the diesel engine in yard trucks, distribution trucks and more.”
This vision for the future was quite a bit hazier just a few years ago, when Ballard and other fuel cell manufacturers were unsure of where the technology might be headed.
“We’ve been a believer in this for years, but we knew a lot of good work had to happen,” says Schubak. “We have growth projections for North America, but there is also the global market to consider. We expect sales to double annually in coming years, and that’s not where we were two or three years ago.” M
Hydrogen fuel cells on the riseManufacturer predicts strong future for the newest lift truck power supply.
18 A u g u s t 2 0 1 1 / Modern Materials Handling m m h . c o m
lift truck TIPS
By Josh Bond, Contributing Editor
Josh Bond is a contributing editor to Modern and can be reached at [email protected].
MMH1108_LiftTruckNews_Tips.indd 18 8/10/11 11:22 AM
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20 A U G U S T 2 0 1 1 / MODERN MATERIALS HANDLING mmh.com
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mmh.com MODERN MATERIALS HANDLING / A U G U S T 2 0 1 1 21
The Container Store:Lift trucks contain the chaos The retailer’s lift truck distributor
played a key role in optimizing
a new distribution center and
securing a 30% improvement
in process time. By Bob Trebilcock, Executive Editor
You would expect a company known as the original storage and organizational retailer to be, well, organized when it comes to stor-age in its new distribution center. And, that is certainly the case at the 1.1-million-square-foot facil-ity The Container Store built in Coppell, Texas.
The facility stands out not just for its efficient use of stor-age, but also for the role played by its lift truck distributor (Malin Integrated Handling Solutions, malinusa.com) and manufac-turer (Raymond, raymondcorp.com) in the design and planning of the DC.
The Container Store worked closely with the distributor on the
racking layout and slotting. By optimizing the design and mate-rial flow through the facility, The Container Store was able to right size its lift truck fleet while simul-taneously improving operations and adding 350,000 square feet of space. Among the most impor-tant measures of success: a 30% improvement in process time.
“When you’re expanding from 450,000 square feet to 800,000 square feet, one of the biggest concerns is travel time,” says Mike Coronado, distribution direc-tor. “The fact that we saw a 30% improvement in travel time while expanding the space our associ-ates cover is the true measure of the success of the project.”
While The Container Store is using just 800,000 square feet
today, it has the option of adding the additional 300,000 square feet in the future. The facility enables a centralized distribution concept, servicing the retailer’s 49 retail stores—each of which receives full truckload replenishment deliveries—as well as a growing direct-to-consumer business.
The facility makes the most of conventional warehouse processes with a fleet comprised of 51 lift trucks:
• 24 pallet trucks for floor-level, primary picking to process daily orders,
• 15 double-deep reach trucks for moving pallets from the dock into the racking reserves and mov-ing reserves down to primary loca-tions on the floor level,
• 4 stand-up counterbalanced trucks for unloading tractor trailers,
• 4 orderpickers for a few
MODERN system report
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22 A u g u s t 2 0 1 1 / Modern Materials Handling mmh.com
specified areas with above-ground level picking and cycle counts,
• 2 tow tractors for moving trash hoppers and recycling materials to compactors, and
• 2 sit-down counterbalanced trucks for moving heavier loads.
In addition, conventional materi-als handling processes are enhanced through best-of-breed warehouse and labor management software solutions as well as slotting, dock and yard man-agement applications developed in-house by The Container Store.
Most importantly, Coronado says, the facility demonstrates The Container Store’s commitment to long-term part-nerships with its vendors and input from all of its associates. “We are an employee-first culture,” he says. “We established focus groups to involve our floor personnel in the selection of criti-cal equipment, such as the lift truck and rack vendors.”
Let’s get organized The first Container Store opened in Dallas in 1978. The small, 1,600-square-foot space offered a never-before-assem-bled collection of storage and organiza-
tion products designed to save time and space and simplify its customers’ lives. In doing so, it originated a completely new category of retailing, that of storage and organization. Since then, the com-pany has experienced continuous dou-ble-digit growth. Today, 49 stores across the country average 25,000 square feet and offer more than 10,000 innovative products. Store No. 50 will open soon.
The need for a new distribution center became apparent back in 2002. At the time, The Container Store was operating from a 350,000-square-foot facility, with 300,000 square feet committed to distribution. The remainder housed corporate office space. In addition, the retailer had a satellite facility with 150,000 square feet. A 10-year sales growth projec-tion study concluded that a larger facility would be necessary to contain its distribution center and corporate offices.
That study led to two years of plan-ning to develop and build the new DC. During that time, Coronado and his distribution and logistics manage-ment team had the challenging task of designing the DC, filling it with new
modern system report
the Container store’s employee-first culture led to the installation of overhead fans to keep the facility cool. associates played a key role in the selection of equipment in the dC.
MMH1108_SySRpt_ContainerStory.indd 22 8/10/11 1:31 PM
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equipment and getting all systems inte-grated and running.
One of the questions the team con-sidered was whether to alter the distri-bution strategy. Instead of offices and order fulfillment activities under one roof, would a network of regional distri-bution centers be more cost effective? The answer, at least for then, was no. “At this point in our growth cycle, it still makes sense for us to service our busi-ness from one central DC, even with high fuel prices,” Coronado says.
A centralized DC also made sense from the viewpoint of The Container Store’s unique corporate culture, a culture that influenced the design of the facility. “Our employee-first cul-ture influences everything we do,” says Coronado. “We believe that communi-cation is leadership. Having all of our operations under one roof is consistent with that philosophy.” For instance, the retailer’s merchandise buying team is located at the facility. “If we have a problem with a product, we can solve it together right here,” Coronado says.
Among the goals for the new facility were to:
• maintain and improve productivity while expanding the size of the facility,
• integrate direct-to-consumer and store replenishment activities in one facility, to keep one inventory that could satisfy both types of orders, and
• create an employee-friendly work environment, despite the high heat and humidity in that part of Texas. “We wanted world-class distribution in an environment that would reflect that we are the best company to work for in America,” Coronado says.
To accomplish those goals, The Container Store worked with a lift truck distributor and materials handling inte-grator in nearby Addison, Texas.
“We knew that attention to the selection of equipment and the layout of the facility was going to be critical to if we were going to improve produc-tivity,” Coronado says. “They came to understand our business completely, so that we had a real trust when they told
us what would work and what would not work.”
Among the major changes imple-mented:
Lift truck changes: Replacing turret trucks that serviced very narrow aisle racks (5-foot aisles and 20-feet of storage) with reach trucks to service 30-foot tall, double-deep pallet racks with 11-foot aisles.
Storage changes: Implementing a new slotting strategy built around keeping the best sellers close to the dock doors and slow moving items in less convenient locations.
A new slotting strategy has a signifi-cant impact on equipment selection, along with productivity. “We wanted to keep a five-day supply of our fastest-moving SKUs in a forward pick loca-tion, whether that supply is five cases or 500 cases,” Coronado explains. “The slotting strategy went a long way to
determining the kind of rack we needed as well as the lift trucks that would be required to service them.”
For instance, double-deep racks and reach trucks are used for SKUs with multiple pallets in a forward pick loca-tion while stockpickers are used for high bay replenishment of slower mov-ing SKUs and riders are used for case picking in zones.
Today, he adds, “We continuously reslot. It is imperative if we’re going to utilize the cube of the space and mini-mize the travel time of our pickers.”
Coronado credits the slotting strategy with improving material flow through the facility, despite the increased size.
Leveraging associates The Container Store’s employee-first culture also played a critical role in the design of the facility and the selection of the equipment.
modern system report
More than 50 lift trucks, including pallet trucks (shown) for floor-level processes like primary picking, keep the facility humming.
MMH1108_SySRpt_ContainerStory.indd 24 8/10/11 1:31 PM
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MODERN system report
To leverage the insight and experi-ence of the associates who would be using the equipment each day, The Container Store set up focus groups to test, analyze and choose the best equip-ment and racking to do their jobs. “All of our employees have a sense of own-ership,” Coronado says.
For instance, Coronado and his team narrowed down the list of poten-tial reach truck vendors to three. At that point, a focus group of associates on the floor evaluated reach trucks from each of the three vendors for six weeks before making a recommendation. Similar focus groups were involved in the selection of the racking and battery management systems.
That employee-first culture influ-enced the working environment of the facility. Instead of the industrial grey color common to most distribution cen-
ters, The Container Store chose a color scheme based on the Dutch painter Piet Mondriaan, using bright, primary colors. The retailer also worked with engineers to install 71 high-velocity, low-speed fans and 48-inch exhaust fans. The fans are part of a building automation system that controls the lighting and fans in the building to keep it as cool as possible in the Texas heat.
“Sensors only turn on the lighting when someone is working in an area,” Coronado says. “The system also oper-ates the fans based on the temperature and humidity inside and outside of the facility.” For instance, in the mornings, when it is likely to be cooler outside than inside, exhaust fans move warm air out of the building. The low-speed fans, meanwhile, keep air in the build-ing moving. One day last August, the temperature inside the DC was 86
degrees when the outside reached 105.
Staying organizedWhile the facility has been up and run-ning for several years, The Container Store continues to tweak the design.
In the near future, for instance, Coronado is adding voice recognition to improve picking processes. “We think our productivity will improve, accuracy will improve and safety will improve,” he says.
As with the selection of lift trucks, The Container Store established a focus group of floor associates, who are eager to bring in the new technol-ogy. “All of our indicators reflect con-tinuous improvements year over year,” Coronado adds. “But what we also cele-brate is that our people feel and believe that they are working in a world-class distribution center.” �
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MMH1108_SySRpt_ContainerStory.indd 26 8/10/11 1:31 PM
28 A u g u s t 2 0 1 1 / Modern Materials Handling mmh.com
modern system report
The Container Store’s Coppell, Texas, facility was designed to manage store replenishment and
direct-to-consumer order fulfillment. Receiving: Inbound shipments are
delivered on Monday through Friday. The facility receives (1) between 25 to 30 loads per day and 75% of shipments are floor-loaded containers or trail-ers. Once the inbound receivers iden-tify the vendor and verify the receipt against a purchase order, the merchan-dise is either palletized at the dock (2) or conveyed to a palletizing station at the dock. Product is scanned to a pallet that is tracked in the warehouse man-
agement system (WMS) by a license plate bar code. The Container Store uses yellow license plate bar codes so that it is easier for associates to identify which pallets are ready for storage.
Putaway: Storage is directed by the WMS. Once a lift truck driver scans a license plate bar code, the WMS chooses a putaway location in the reserve storage areas located through-out the facility (3). Putaway is done with reach trucks.
Picking: A system planner will ana-lyze the direct-to-consumer and replen-ishment orders available for fulfillment and will determine what work will be
“launched,” or initiated, each morning. That, in turn, sends a signal to the ship-ping department to plan the transporta-tion that will be required to ship orders. Finally, orders are also sent to the labor management system, which determines how many hours will be required to fill the orders. The work is also distributed across the 18 different picking zones (4) where product is stored. Product is slotted in picking zone based on a vari-ety of criteria, including the velocity of movement, the type of product and full case and split-case picks.
Store replenishment: Based on the orders and time required to fill
The Container Store, Coppell, Texassize: 1.1 million square feet available/810,000 square feet in use
Products: storage and organization products
sKus: 10,000
tHrougHPut: 75 truckloads per week average/120 truckloads per week during peak
sHifts: 7 days/2 shifts
eMPloyees: 240 to 300, depending on seasonal fluctuations
Getting organized, improving productivity A close attention to layout, design and equipment selection makes the most of conventional materials handling processes in The Container Store’s DC.
By Bob trebilcock, Executive Editor
1
Receivingdocks
10
Direct-to-consumershipping 9
Direct-to-consumerstaging
8Direct-to-consumerconveyor
4
Picking
4
Picking
4
Picking
4
Picking
7
Direct-to-consumerpacking
4
Picking
4
Picking
3
Reservestorage
3
Reservestorage
3
Reservestorage
1
Receivingdocks
6
Truckloadshipping2
Receivingprocessing
5Truckload
staging
2Receivingprocessing
MMH1108_SySRpt_ContainerStory.indd 28 8/10/11 1:31 PM
Modern Materials Logistics Management Supply Chain Management
• Automation
• 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
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MODERN system report
them, shift supervisors assign associ-ates to the pick zones (4). They receive work assignments on an RF scanning device and pick to a pallet. In addition to telling an associate what to pick, the system also tells them how long each assignment should take based on the engineered labor standards in the labor
management system. The system will tell the associate where to start pick-ing, when the order is complete, direct them to the staging location (5) on a dock for full truckload shipments (6)and finally, direct them to their next assignment.
Direct-to-consumer: The pro-
System design and integration: Malin Integrated Handling Solutions, malinusa.com
Lift trucks: Raymond, www.raymondcorp.com
Battery system: Carney Battery Handling, www.carneybatteryhandling.com
Consulting group: St. Onge, www.stonge.com
Conveyor: Hytrol, www.hytrol.com
Pallet rack: Frazier Industrial Rack, www.frazier.com
WMS: Catalyst (CDC Corp), www.cdccorpo-ration.net/en/Catalyst.aspx
Labor management: RedPrairie, www.redprairie.com
Slotting, yard and dock management software: The Container Store
Bar code scanning: Motorola Solutions, www.motorolasolutions.com
Voice recognition: Lucas Systems, www.lucasware.com
High-velocity fans: MacroAir Technologies, www.macro-air.com
System suppliers
cess for direct-to-consumer orders is similar to store replenishment, except that orders are picked to a cart. Each cart can accommodate 9 to 12 orders at a time, which are picked in batches. Once a batch has been picked, the associate delivers the cart to a pack-ing station (7), where the orders are packed for shipment. The associate is then assigned to another cart.
Shipping: Pallets for store replen-ishment are staged at the dock door (5)assigned to that order. The majority of the trailers (6) are floor loaded. Depending on the product, trailers are maximized by cube or weight. To initiate the process, the loader scans the license plate bar code of the pallet he is working on, and con-tinues loading until the trailer is complete.
Since stores have minimal stock rooms, most deliveries are made at 5 a.m. so that store associates have time to unload trucks and move product directly to the floor. For that reason, trailers are loaded by 3 p.m. each day.
For direct-to-consumer orders, once a packager finishes an order, the cases are placed on a conveyor (8) and delivered to a manifest point (9). Shipping labels are applied and the cases are loaded directly into the parcel shipper’s trailers (10).
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MMH1108_SySRpt_ContainerStory.indd 30 8/10/11 1:31 PM
lift truck suppliers
With sales on the rise for the second consecutive year, the worldwide industrial lift truck market is revved up.
By Lorie King Rogers, Associate Editor
Last year, Modern’s Top 20 lift truck suppliers story started on an upbeat note. It read: The worldwide industrial lift truck industry spent the better part of 2009 in a rut. Sales were down 39%, but it appears the worst may be over.
So, one year later, did we get it right? Not only did we hit the right note, we watched the lift truck industry take it even higher than expected. Last year when Modern spoke with Jeff Rufener, president of the Industrial Truck Association (ITA, www.indtrk.org) and vice pres-
ident of marketing for Mitsubishi Caterpillar Forklift of America, industry sales figures were up 40% over the same time period as the previ-ous year. But he didn’t expect that rate to con-tinue throughout 2010. Happily, Rufener admits he was wrong. That rate of increase held up, and North American distributors saw 2010 orders finish up 40% better than in 2009.
Hold on, though; Rufener still is cautious. He says business was good last year and is better than expected this year, but it’s still fragile.
modern special report
m m h . c o m ModeRn MateRiaLs HandLing / A u g u s t 2 0 1 1 31
MODEL 7400 REACH-FORK® TRUCK
At Raymond, we believe the key to success of your warehouse operations is effi cient material handling. That’s what we call Raymond Eco-Performance. Every Raymond® lift truck is designed and engineered to provide the maximum economic and ecologic benefi ts, so your warehouse operation saves power, creates power, lowers costs, and increases productivity.
Scan this QR code with your smartphone for exclusive content.
How effi cient is your fl eet?Learn more about Raymond Eco-PerformanceCall today • 1-800-235-7200
©2011 The Raymond Corporation, Greene, NY
$
SAVES POWER Raymond’s exclusive ACR System™ provides longer run-times between charges, which results in reduced battery changes, reduced kilowatt use, and reduced CO2 emissions as well.
CREATES POWER With regenerative braking, Raymond lift trucks save energy and result in less brake wear. When lowering their forks, they also extend battery life.
LOWERS COSTS Raymond lift trucks provide you a lower cost per pallet move. And by requiring less labor, it extends the life of your trucks themselves.
INCREASES PRODUCTIVITY Raymond lift trucks move more pallets per hour than competing models. Faster cycle times and more pallets mean less downtime and more performance.
MMH1108_Top20_RaymondGatefold2.indd 3 8/4/11 9:05 AM
ECO-PERFORMANCE
SAVESPOWER.CREATESPOWER.
MMH1108_Top20_RaymondGatefold2.indd 1 8/4/11 8:54 AM
lift truck suppliers
MODEL 7400 REACH-FORK® TRUCK
At Raymond, we believe the key to success of your warehouse operations is effi cient material handling. That’s what we call Raymond Eco-Performance. Every Raymond® lift truck is designed and engineered to provide the maximum economic and ecologic benefi ts, so your warehouse operation saves power, creates power, lowers costs, and increases productivity.
Scan this QR code with your smartphone for exclusive content.
How effi cient is your fl eet?Learn more about Raymond Eco-PerformanceCall today • 1-800-235-7200
©2011 The Raymond Corporation, Greene, NY
$
SAVES POWER Raymond’s exclusive ACR System™ provides longer run-times between charges, which results in reduced battery changes, reduced kilowatt use, and reduced CO2 emissions as well.
CREATES POWER With regenerative braking, Raymond lift trucks save energy and result in less brake wear. When lowering their forks, they also extend battery life.
LOWERS COSTS Raymond lift trucks provide you a lower cost per pallet move. And by requiring less labor, it extends the life of your trucks themselves.
INCREASES PRODUCTIVITY Raymond lift trucks move more pallets per hour than competing models. Faster cycle times and more pallets mean less downtime and more performance.
MMH1108_Top20_RaymondGatefold2.indd 4 8/4/11 9:05 AM
modern special report
Class 1, Lift Code - 1
Counterbalanced Rider Type, Stand Up
Class 1, Lift Code - 4
Three Wheel Electric Trucks, Sit Down
Class 1, Lift Code - 5
Counterbalanced Rider, Cushion Tires, Sit Down
Class 1, Lift Code - 6
Counterbalanced Rider, Pneumatic or Either Type Tire, Sit Down
Class 2, Lift Code - 1
High Lift Straddle
ITA’s lift truck classifications
The Industrial Truck Association (ITA, www.indtrk.org) has defined seven classes of lift trucks, or forklifts, which are defined by the type of engine, work environment, operator position and equipment characteristics. Forklift classes include:• Class 1: electric motor trucks with
cushion or pneumatic tires• Class 2: electric motor narrow
aisle trucks with solid tires
• Class 3: electric hand trucks or hand/rider trucks with solid tires
• Class 4: internal combustion engine sit down rider forklifts with cushion tires, suitable for indoor use on hard surfaces
• Class 5: internal combustion engine sit down rider forklifts with pneumatic tires, suitable for outdoor use on rough surfaces
• Class 6: electric or internal combustion engine powered, rider
units with the ability to tow (rather than lift) at least 1,000 pounds• Class 7: almost exclusively
powered by diesel engines with pneumatic tires, these units are suitable for rough terrain and used outdoors.
Since mostly classes one through five are used in materials handling applications inside the four walls, Modern has only specified those on our supplier table.
ITA’s lift truck classes
One reason for the fragile condition is manufactur-ing. Manufacturing had been a bright spot in the eco-nomic recovery, says Rufener, but that has started to slow recently. Meanwhile, unemployment is above 9% and gas is hovering at $4 a gallon.
On the up side, one solid contributor to the lift truck industry’s annual growth is the fact that capital goods are a cyclical business. “Later on in 2010, we saw deal-ers rebuilding inventory and replenishing their rental fleets, which they hadn’t done in several years,” Rufener says. “This reflects increased customer demand and is
a direct reflection of the economic activity dealers see in their territory and in their expectations for future growth.”
Back in blackSo, the future looks good, but what about today? That’s also looking good, and the proof is in the numbers. According to ITA’s worldwide industrial truck figures, shipments were up 132% in 2010. (See the “Worldwide lift truck market” table.)
This is not just a North American phenomenon: Last
Worldwide lift truck market Orders Shipments
Region 2009 2010 % Change 2009 2010 % Change
Europe 200,311 259,932 130% 207,082 245,512 119%
Americas 118,929 181,060 152% 128,246 152,160 119%
Asia 206,531 322,953 156% 207,207 314,307 152%
Africa 9,721 15,534 160% 9,953 14,243 143%
Oceania 11,340 14,973 132% 12,451 14,468 116%
Total 546,832 794,452 145% 561,939 740,690 132%
Source: These figures are from the World Industrial Truck Statistics organization.
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Class 2, Lift Code - 1
High Lift Straddle
Class 2, Lift Code - 2
Order PickerClass 2, Lift Code - 3
Reach Type Outrigger
Class 2, Lift Code - 4
Side Loaders, Turret Trucks, Swing Mast and Convertible Turret/Stock Pickers
Class 2, Lift Code - 6
Low Lift Pallet and Platform (Rider)
Class 3, Lift Code - 1
Low Lift Platform
Top 20 lift truck suppliers in 2010
Rank Company 2009 Rank 2010 revenue* North American brands World headquarters
ITA class of trucks manufactured
Class 1 Class 2 Class 3 Class 4 Class 5
1 Toyota Industries Corp. 1 $5.9 billion Toyota, Raymond Aichi, Japan x x x x x
2 Kion Group 2 $4.7 billion Linde, Still OM, Baoli Wiesbaden, Germany x x x x x
3 Jungheinrich Lift Truck Corp. 3 $2.4 billion Jungheinrich Hamburg, Germany x x x x
4 Crown Equipment Corp. 4 $1.8 billion Crown, Hamech New Bremen, Ohio x x x x x
4 NACCO Industries 5 $1.8 billion Hyster, Yale Cleveland, Ohio x x x x x
6 Mitsubishi Caterpillar Forklift 6 $1.2 billion Mitsubishi, CAT Sagamihara, Japan x x x x x
7 Komatsu Utility Co. 7 $1 billion Komatsu, Tusk Tokyo, Japan x x x x x
8 Nissan Forklift Corp. 9 $900 million Nissan, Barrett, Atlet Tokyo, Japan x x x x x
9 TCM Corp. 10 $889 million TCM Tokyo, Japan x x x x
10 Anhui Forklift Group 8 $777 million Heli Hefei, Anhui, China x x x x x
11 Nippon Yusoki Co. 11 $747 million Not available in North America Kyoto, Japan x x x
12 Clark Material Handling 13 $570 million Clark Seoul, South Korea x x x x x
13 Doosan Infracore 12 $475 million Doosan Infracore Seoul, South Korea x x x x x
14 Zhejiang Hangcha Engineering Machinery Co.
15 $313 million** HC Hangzhou, China x x x x x
15 Hyundai Heavy Industries 16 $258 million Hyundai Ulsan, South Korea x x x x
16 Tailift 17 $125 million** Tailift, World-Lift Taichung, Taiwan x x x x
17 Combilift 18 $110 million Combilift Monaghan, Ireland x x x
18 Hubtex 20 $75 million** Hubtex Fulda, Germany x x x x x
19 Hytsu 19 $69 million Hytsu Shanghai, China x x x x x
20 Godrej & Boyce Manufacturing NA $67 million Not available in North America Mumbai, India x x x x x
*Fiscal year 2010 worldwide sales revenue; figures based on foreign exchange rates as of 12/31/10.
**Figure based on industry estimate
year, shipments were up around the globe. • Asia experienced the biggest jump, with a 152%
increase in shipments. The region went from a 23% decline in 2009 shipping 207,207 units to shipping 314,307 units in 2010.
• Africa was right up there with an increase of 143%. After shipping 9,953 units in 2009 and expe-riencing a 40% decline, the African region shipped 14,243 units in 2010.
• Europe shipped 245,512 units in 2010, which
m m h . c o m Modern Materials Handling / A u g u s t 2 0 1 1 34
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Class 3, Lift Code - 1
Low Lift Platform
Class 3, Lift Code - 2
Low Lift Walkie Pallet
Class 3, Lift Code - 3
Tractors (Draw Bar Pull Under 999 lbs.)
Class 3, Lift Code - 4
Low Lift Walkie/Center Control
Class 3, Lift Code - 5
Reach Type Outrigger
Class 3, Lift Code - 6
High Lift Straddle
Top 20 lift truck suppliers in 2010
Rank Company 2009 Rank 2010 revenue* North American brands World headquarters
ITA class of trucks manufactured
Class 1 Class 2 Class 3 Class 4 Class 5
1 Toyota Industries Corp. 1 $5.9 billion Toyota, Raymond Aichi, Japan x x x x x
2 Kion Group 2 $4.7 billion Linde, Still OM, Baoli Wiesbaden, Germany x x x x x
3 Jungheinrich Lift Truck Corp. 3 $2.4 billion Jungheinrich Hamburg, Germany x x x x
4 Crown Equipment Corp. 4 $1.8 billion Crown, Hamech New Bremen, Ohio x x x x x
4 NACCO Industries 5 $1.8 billion Hyster, Yale Cleveland, Ohio x x x x x
6 Mitsubishi Caterpillar Forklift 6 $1.2 billion Mitsubishi, CAT Sagamihara, Japan x x x x x
7 Komatsu Utility Co. 7 $1 billion Komatsu, Tusk Tokyo, Japan x x x x x
8 Nissan Forklift Corp. 9 $900 million Nissan, Barrett, Atlet Tokyo, Japan x x x x x
9 TCM Corp. 10 $889 million TCM Tokyo, Japan x x x x
10 Anhui Forklift Group 8 $777 million Heli Hefei, Anhui, China x x x x x
11 Nippon Yusoki Co. 11 $747 million Not available in North America Kyoto, Japan x x x
12 Clark Material Handling 13 $570 million Clark Seoul, South Korea x x x x x
13 Doosan Infracore 12 $475 million Doosan Infracore Seoul, South Korea x x x x x
14 Zhejiang Hangcha Engineering Machinery Co.
15 $313 million** HC Hangzhou, China x x x x x
15 Hyundai Heavy Industries 16 $258 million Hyundai Ulsan, South Korea x x x x
16 Tailift 17 $125 million** Tailift, World-Lift Taichung, Taiwan x x x x
17 Combilift 18 $110 million Combilift Monaghan, Ireland x x x
18 Hubtex 20 $75 million** Hubtex Fulda, Germany x x x x x
19 Hytsu 19 $69 million Hytsu Shanghai, China x x x x x
20 Godrej & Boyce Manufacturing NA $67 million Not available in North America Mumbai, India x x x x x
*Fiscal year 2010 worldwide sales revenue; figures based on foreign exchange rates as of 12/31/10.
**Figure based on industry estimate
resulted in 119% increase after experiencing a decline of 48% in 2009.
• The Americas also experienced a 119% increase in 2010 after a decline of 43% in 2009. The region shipped 152,160 units in 2010, compared to 128,246 in 2009.
• Oceania also overcame a 48% decline. In 2009 the region shipped 12,451 units, compared to 14,468 units in 2010, resulting in a 116% increase.
In total, worldwide shipments rose from 561,939 in 2009 to 740,690 in 2010, an impressive 132% increase. With the numbers calculated and each of the worldwide regions performing well, the Top 20 lift truck suppliers also performed well independently.
The Top 10The top suppliers are at the top of the list again this year and almost in the exact order. Last year’s leading suppliers —Toyota, Kion, Jungheinrich, NACCO and Crown—continue to own the top five positions. (See the table for the complete list of suppliers.)
Toyota, which manufactures Toyota and Raymond brands, remains at No. 1 with $5.9 billion in revenue, up from $4.6 billion in 2009. The Kion Group, which includes North American brands Linde, Still, OM and Baoli, retains the No. 2 position with $4.67 billion in rev-enue, up from $4.1 billion.
Jungheinrich holds on firmly to the No 3. spot with $2.4 billion in revenue, up slightly from $2.3 billion in 2009. Crown and NACCO, which ranked in the No. 4 and No. 5 positions in 2009, respectively, both come in at $1.8 billion and share the No. 4 position. Crown saw an increase in revenue up from $1.6 billion, while NACCO, which includes North American brands Hyster and Yale, rose from $1.5 billion.
The five remaining top 10 lift truck suppliers are also back, with only a slight variation in the order. Rounding out the top 10 are Mitsubishi Caterpillar Forklift, back in No. 6 position; Komatsu, back in the No. 7 position; Nissan moving up one position to No. 8; TCM Corp. also moving up one position to No. 9; and Anhui Forklift Group dropping two positions to No. 10.
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Class 3, Lift Code - 7
High Lift Counterbalanced
Changes in the line upAbsent from this year’s list is the French supplier Manitou. While the company has had a good year, its company spokesperson told Modern the company pre-ferred to be removed from the list because it supplies mostly rough terrain vehicles and doesn’t compete with the majority of suppliers on this list.
New to the list this year is India’s Godrej & Boyce Manufacturing. In last year’s story, we suggested keeping an eye on the emerging lift truck market in India. This year it paid off for Godrej & Boyce Manufacturing as the company makes its first appearance on Modern’s Top 20 list in the No. 20 position with $67 million in revenue.
The BRIC marketIndia is one of the four countries that comprise what the lift truck industry refers to as BRIC, which is an acro-nym for the combined countries of Brazil, Russia, India and China. In 2010, BRIC’s lift truck market was up 84% over 2009, and through the first quarter of 2011, it was up 44% over 2010. According to Rufener, there are huge rates of growth in these emerging markets. And, of
the four BRIC countries, Rufener says, China is domi-nant, accounting for about 80% of total demand.
In the coming months, we’ll keep an eye on the B in BRIC. Brazilian supplier Paletrans came close to mak-ing this year’s list, with $55 million in revenue.
Making the listTo make Modern’s Top 20 list this year, suppliers had to make at least $67 million in revenue in 2010. As a point of comparison, the cut off was $60 million in 2009 and $98 million in 2008.
The top five suppliers combined reported revenue of more than $16.6 billion; seven of the top 10 suppliers reported revenue in the billions, as opposed to five in the billions last year.
The combined 2010 revenue for all 20 companies on the list tops $24.17 billion, compared to $20.17 billion in 2009, $28.99 billion in 2008, and $31.67 billion in 2007. While the total isn’t back up to 2007 levels, the numbers are on the rise.
Going forward, going greenAlso on the rise is the continued, ongoing interest in green technology, particularly the demand for electrics. “We’re seeing, and will continue to see, an increase in electrics,” says Rufener. “Even with strong economic recovery and dealer growth, electrics are still 60% of the mix and are expected to exceed that percentage sold in North America.”
According to Rufener, we’re seeing more compa-nies embrace green technology simply for sake of being able to demonstrate a commitment to environment. “Companies are willing to spend money to go green and are not be driven solely by the cost-benefit analy-sis,” Rufener says. “Every application is different. While some prove it to be cost effective, others that aren’t so clear, but companies will go green for sake of environ-mental responsibility.”
To be eligible for Modern’s annual Top 20 lift truck suppliers ranking, companies must manufacture and sell lift trucks in at least one of the Industrial Truck Association’s (ITA) seven truck classes: electric motor rider; electric motor hand trucks; internal combustion engine; pneumatic tire; electric and internal combustion engine tow tractors; and rough terrain for lift trucks.
Rankings are based on worldwide revenue from powered industrial trucks during each company’s most recent fiscal year. Revenue figures submitted in foreign currency are calculated using the Dec. 31, 2010 exchange rate.
How the suppliers are ranked
Class 3, Lift Code - 8
Low Lift Walkie/Rider Pallet
Class 4, Lift Code - 3
Fork, Counterbalanced (Cushion Tire)
Class 5, Lift Code - 4
Fork, Counterbalanced (Pneumatic Tire)
m m h . c o m Modern Materials Handling / A u g u s t 2 0 1 1 36
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Find what you’re looking for.
www.MMH.comA true industry resource for materials handling.
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mmh.com MODERN MATERIALS HANDLING / A U G U S T 2 0 1 1 39
W
MODERN Equipment 101: Lift trucksA primer for warehouse/DC managers
By Lorie King Rogers, Associate Editor
Lift trucks have come a long way since their introduction
in the materials handling arena in the 1920s. Today, they are
smarter and stronger, and still the indispensable workhorses
in our warehouses and distribution centers.
Lift truck basics
hen lift trucks were introduced nearly 100 years ago, they were simple pieces of motorized equipment designed to move pallet loads from point A to point B. Today, sophisticated lift trucks are available in a combination of designs, weight capacities and lifting heights. The vehicles also come with a variety of enhanced safety features and ergonomic designs for operator comfort.
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Perhaps the only universal features of today’s diverse selection of lift trucks are the forks used to lift loads and the tires used to move them.
This article looks at the basic design and application of several types of lift trucks used in manufacturing, ware-housing and distribution:
Counterbalanced lift trucks • Electric trucks • Internal combustion (IC) trucks
Narrow-aisle lift trucks• Reach trucks • Turret trucks • Orderpickers
Low lift pallet trucks (or pallet jacks)
• Non-powered pallet trucks• Electric-powered pallet trucks
COUNTERBALANCED TRUCKSThe most common type of lift truck, also known as a forklift, is the coun-terbalanced, sit-down truck. A weight located in the rear of one of these trucks counterbalances the weight of the load, ensuring the truck doesn’t tip forward.
A typical counterbalanced lift truck has:• a capacity of 4,000 to 6,500 pounds;• a lifting height of about 16 feet
(with 189 inches being the most pop-lar);
• and comes outfitted with lights, backup alarms and other safety features.
Counterbalanced trucks are pow-ered either by internal combustion (IC) engines or electric motors. The split is about 40% IC and 60% electric, according to Jeff Rufener, president of the Industrial Truck Association (ITA, www.indtrk.org) and vice president of marketing for Mitsubishi Caterpillar Forklift America.
Electric counterbalanced lift trucks Electric trucks, which make up about 60% of the market, get their power from large, heavy lead-acid batteries, which provide much of the counterweight.
The ITA classifies electric counter-balanced trucks as Class 1 lift trucks. Class 1 also includes stand-up coun-terbalanced trucks and other electric trucks built for general use.
While the initial investment in an electric truck is more than IC trucks, electric trucks are less expensive to operate, due to lower fuel and mainte-nance costs.
Most of the electric rider trucks shipped in North America are moving material inside the four walls. “Electric trucks have historically been limited to indoor applications that are clean,” explains David McNeill, manager of product strategy for electric riders at NACCO Materials Handling Group. “However, with the launch of several new Class 1 products, it is becoming increasingly possible to use electric rider products in some outdoor applications.”
Compared to IC trucks, electric trucks are the preferable indoor choice because they are quiet, produce no emissions and can usually run a full eight-hour shift on one battery charge. Removing, recharging and reload-ing batteries—which typically weigh around 3,000 pounds—can be cumber-some and time consuming and usually requires a dedicated space for battery handling. Newer fast charging tech-nologies, however, are changing that paradigm.
One new charging technology is called opportunity charging. “This basi-cally means that rather than waiting until the end of the shift to recharge the battery, it happens throughout the day,” explains Niels Ostergaard, CSSR training manager for Toyota Material Handling U.S.A. “When the truck is parked for a break, the operator takes the opportunity to plug it in at charging stations located throughout the facility.”
Fast-charging is another enhanced charging technology. According to Ostergaard, advances in battery tech-nology and charging systems make it possible to cut charging time by as much as 50%.
Internal combustion counterbalanced lift trucks IC engine trucks run on a variety of fuels, including gasoline, diesel, liquid propane gas (LPG) and compressed natural gas (CNG). The larger lift trucks, which are used outdoors, are
modern Equipment 101: Lift trucksA primer for warehouse/DC managers
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typically gasoline- or diesel-powered and have pneumatic tires that make them suitable for rough terrain and steep inclines as opposed to cushion tires, which are made of solid rubber and are best for indoor applications on smooth surfaces.
LPG is the most common fuel for indoor trucks. With more than 600,000 propane-fueled lift trucks in opera-tion today in warehouses and DCs, these units offer a number of ben-efits. For example, propane-fueled lift trucks maintain consistent, 100% power throughout operation and have faster ground speeds than other power sources. They can also run 24 hours a day, with longer run times between refueling than lift trucks fueled by other power sources, according to Brian Feehan, vice president of Propane Education & Research Council (PERC, www. propanecouncil.org).
One important consideration when choosing a propane-fueled lift truck is where the refueling area will be located. Propane cylinders require little space and can be kept in a storage area inside or outside of a facility. And while it takes little time to switch out a pro-pane cylinder, it does require operator training and knowledge of safety stan-dards like the Occupational Health and Safety Administration (OSHA, www.osha.gov) Standard 1910.178.1, says Feehan.
Compared to electric trucks, IC trucks are quicker and easier to refuel,
but they can be noisy and produce air-polluting emissions. The federal Environmental Protection Agency (EPA, www.epa.gov) and the California Air Resources Board (www.arb.ca.gov) have set standards that limit emis-sions. The Industrial Truck Standards Development Foundation (ITSDF, www.itsdf.org) also offers a number of lift truck standards on their Web site free of charge.
The ITA classifies internal combus-tion counterbalanced lift trucks with cushion tires as Class 4 trucks and those with pneumatic tires as Class 5.
NARROW-AISLE LIFT TRUCKSThe ITA’s Class 2 includes a variety of electric lift trucks built for use in nar-row aisles.
At 12 feet wide, standard stor-age aisles allow a counterbalanced lift truck to turn in the aisle and put away a load. Narrow aisles are typically only 8 feet wide—and very narrow aisles are only 5.5 to 6 feet wide—requiring specialized lift trucks that can put away loads without turning or that are small enough to make tight turns.
Three of the most common narrow-aisle trucks are reach trucks, turret trucks and orderpickers.
Narrow-aisle reach trucks Reach trucks are considered the origi-nal narrow-aisle lift truck. These trucks are small enough to turn in narrow aisles because they don’t need a large
counterweight. Instead, outrigger arms extend in front of the trucks to provide stability. The outrigger arms, however, can prevent the trucks, depending on storage configuration, from getting close enough to the storage rack to deposit and retrieve loads. To overcome this, a reach truck is designed with a telescoping mechanism—called a pan-tograph—that allows the forks to reach into storage locations.
The best environment for a narrow-aisle lift truck is one that is clean, has good lighting, an ample turning aisle, good traffic flow and well-maintained floors.
Turret trucks The lift truck often chosen for work in very narrow aisles is the turret truck. These trucks have pivoting forks that turn 90 degrees on either side and tra-verse from side to side.
To put away a load, an operator drives down the aisle with the load fac-ing forward and then stops at the desig-nated storage location. The forks pivot to the appropriate side and lift the load to the desired height. Then the forks traverse to their full extension, deposit-ing the load. The forks return to their original position before forward travel resumes.
Turret trucks can be completely operator guided or can run on a wire guidance system—an attractive option in very narrow aisles. In man-up trucks, the operator compartment rises with
typically gasoline- or diesel-powered counterweight. Instead, outrigger arms
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the load. In man-down trucks, opera-tors remain at floor level.
A good rule of thumb when choos-ing a turret truck is to measure speeds at different elevations and compare mast sway.
Orderpickers While reach trucks and turret trucks are used for storing and retrieving pal-let loads, orderpickers are used for handling individual items or cases. An orderpicker, also known as a stockpicker or order selector, lifts the operator on a platform along with the forks. The operator picks items from bulk storage locations and places them directly onto a pallet on the forks of the truck.
Orderpickers can safely move for-ward while in an elevated position. They can be completely operator-guided or can run on wire guidance systems.
LOW LIFT PALLET TRUCKS The simplest and least expensive lift trucks are non-powered pallet trucks, also known as hand pallet trucks or hand pallet jacks. Powered and non-powered pallet trucks are included in ITA’s Class 3.
Non-powered pallet trucks Non-powered pallet trucks use a lift-ing device—usually hydraulic—to raise pallets just a few inches off the floor. Operators then grab the truck’s handle and pull the load behind them.
Electric-powered pallet trucksElectric-powered pallet trucks are also available. These trucks are easy to maneuver, relatively inexpensive, and available with forks long enough to accommodate two or three pallet loads.
Powered pallet trucks come in two versions, known as “walkies” and “rid-ers.” The walkie is designed for the operator to walk along with the truck, while the rider has a platform on which the operator can stand. These trucks are often used in warehouses for order picking, with operators stacking cartons on pallets as they work their way down the picking aisles.
The right fitOne of the most important factors associated with any lift truck is using the right sized unit for the right appli-cation. The application should always drive the product selection, says
NACCO’s McNeill.As the economy has become more
complex and competitive, customers are looking for efficiencies to lower operat-ing costs while increasing productivity. Lift trucks can play a role in accomplish-ing those goals, says Ostergaard. “In today’s market, it’s critical to ensure that you’re using the proper sized lift for the application. The wrong sized lift truck can have a dramatic negative effect on productivity, profitability and the bottom line. It’s like buying a new pair of shoes. They may be beautiful and priced right, but if the size is wrong, you won’t be able to walk.” �
MODERN Equipment 101: Lift trucksA primer for warehouse/DC managers
Fuel cell-powered lift trucks are pos-sible, but not yet profitable. While fuel cell technology is a promising, emerging technology, it is still depen-dent on government funding, accord-ing to Jeff Rufener, president of the Industrial Truck Association (ITA, www.indtrk.org) and vice president of marketing for Mitsubishi Caterpillar Forklift America (MCFA, www.mcfa.com).
How long that dependent rela-tionship will last is still an open ques-
tion. Government support is key to keeping progress moving forward, but it’s unpredictable. Rufener says, “The technology has been proven viable, but the economics of the technology are not clear. The fuel infrastructure–access to hydrogen and the storage and delivery system– just isn’t there yet.”
Lithium ion batteries are another emerging technology to keep an eye on, but right now Rufener says, the cost raises eyebrows.
Alternative energy sources
Who makes whatFor a list of lift truck suppliers and the types of trucks they manufacture, see p. 34.
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July 2010
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2By Bob Trebilcock, Executive Editor
Today’s lift trucks offer more in the way of
technology, power and performance than ever
before. Here’s a look at the latest innovations
available in today’s trucks.
Remember that old commercial: This is not your father’s Oldsmobile? The same can be said for lift trucks. If you haven’t replaced your fleet of lift trucks in recent years—and, thanks to the recession, many Modern readers parked some of their fleet during 2009—you may be surprised by the technology being built into today’s offerings. The developments include everything from ergonomic improvements for operator comfort to fully automated lift trucks that operate just like an automatic guided vehicle (AGV).
But, not all of the changes are as revo-lutionary as converting a lift truck into an AGV. “We are an evolutionary industry, not a revolutionary industry,” says Jeff
Bowles, product line manager, Mitsubishi Caterpillar Forklift America (MCFA).
If you think about it, that approach makes sense. New lift trucks have to go right to work in existing applications without disrupting operations. What’s more, the basic lift truck remains the backbone of most warehouses, DCs and manufacturing plants. Those evolu-tionary changes are resulting in trucks that are more productive, smarter and reliable than ever before.
Modern recently spoke to 10 of the leading lift truck manufacturers in North America to learn about the 15 most important advancements found on the next generation of lift trucks. Here’s what we learned.
modern information management
15ways the lift truck is evolving
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Automating lift trucks. Automation is coming to lift trucks as Crown, MCFA, Toyota, Nissan and Raymond ready lift trucks that can operate as automatic guided vehicles. Raymond, for instance, has plans to introduce an automated lift truck incorporating a camera-based navigation system from Seegrid in early 2012. The justifica-tion for automation is simple: Labor is expensive. “If you look at the five-year economic life of a lift truck, labor rep-resents 70% to 75% of the total invest-ment,” says Frank Devlin, manager of advanced technologies at Raymond. “If you can maximize your labor force, there is a tremendous need for this.”
Bringing RFID to lift trucks. In addition to automated lift trucks, manufacturers are exploring semi-automated solutions. Through its rela-tionship with Jungheinrich, MCFA is bringing RFID- and transponder-based technologies from Europe to very narrow aisle lift trucks in the North American market. One solution relies on a warehouse navigation system that knows where the truck is located based on encoders and transponders in the floor and RFID tags at the pick and pallet locations. Once order picks are loaded into the system, the truck calcu-lates the most efficient way to pick the orders; it will also calculate the lift and drive speeds that are most productive for the process.
“The system will automatically drive and lift the truck in an automated fash-ion from pick location to pick location without going to a completely auto-mated truck,” says Bowles. MCFA is also installing transponders and sensors on the truck for safer operations. On man-up trucks, for instance, the sys-tem will monitor what’s in front of the truck at the ground level. “It’ll slow the truck until the obstruction is moved
when the operator has limited visibil-ity,” says Bowles.
Remote-controlled trucks. Crown is also developing semi-automated solutions that serve the gap between conventional lift trucks and AGVs: a remote-controlled vehicle for case picking. An order selector can drive the truck into a pick zone; while pick-ing, the operator moves the truck from one pick location to the next using a remote control device. That saves the time usually spent getting on and off the truck between picks. “We are try-ing to bring functionality to the truck that adds value,” says Tim Quellhorst, senior vice president of Crown. “This is a good example of a solution that can drive labor productivity in the less than full automation area of operation.”
Lift truck, phone home. Lift trucks are getting smarter, thanks to telemat-ics—an industry term for the conver-gence of telecommunications and data collection technologies such as sensors and RFID technology. Telematics allow the lift truck to collect data about the operation of the truck and the perfor-mance of the operator and then com-municate that information to a system of record. The onboard computer on a Raymond lift truck, for instance, has the ability to send fault codes and the serial number of a truck by e-mail to a technician’s smart phone or computer. “That allows a technician to diagnose a truck and bring the tools, parts and components they need for the job,” says Devlin.
Integrating the lift truck with the WMS. Most of the information being collected by telematics systems today is being used to support maintenance and fleet management initiatives. The next step, says Jonathan Dawley, vice
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president of marketing for NACCO Materials Handling Group (NMHG), is to integrate telematics with a ware-house management system (WMS). That integration would allow lift truck data to become part of the workflow of a facility. “Using data from the lift truck to improve the productivity of labor could be more important than running your lift truck 1 mph faster,” Dawley says.
The ergonomic lift truck. Ergonomics and worker comfort have long been a priority in Europe, where distributors and manufacturers have a longer term relationship with their employees. That thinking is beginning to permeate U.S. enterprises, especially those with a global footprint. That, in turn, is driving the demand for more European style trucks here in the United States. “We see some of our U.S. and Canadian customers creating a different type of environment for their employees in the warehouse,” says NMHG’s Dawley. “They want a smarter, more productive operator, not a stronger operator.” He believes the attention to ergonomics not only improves productivity, it helps retain skilled employees.
Fingertip controls. Multi-functional controls that can be controlled by an operator’s fingertips are one example of improved ergonomics. With one con-trol, an operator can work the lift of the forks, the tilt angle and the side shifter. “Fingertip controls were introduced in Europe,” says Steve Cianci, direc-tor of marketing and product manage-ment for Nissan Forklift Corporation of North America. “While they’re not popular yet in the United States, we’re seeing increased interest because they provide a more ergonomic experience for the operator.”
Smarter lift trucks. What might the lift truck of the future look like?
According to Lyndle McCurley, sales and marketing manager for Doosan Industrial Vehicles America, it’s a truck that’s smarter, more ergonomic and flex-ible. Last month, Doosan previewed an electric concept vehicle at the British Open. The glass on the truck’s cab is clear when operating indoors and tints to keep out sunshine and heat when it’s operating outside. As the forks are raised, the cabin rises slightly and tilts backward so that the operator can look up at higher elevations without strain-ing his neck. Heads up displays include graphics of the height of the forks, the weight of the load and the tilt angle. Finally, the truck can change its center of gravity and wheel base—automati-cally elongating or retracting the length of the wheelbase—depending on the size of the load and the operating envi-ronment. “Instead of a 5,000-pound truck, we’re developing multi-capacity trucks that can adapt to the operating requirements,” McCurley says.
Inhibitor functions. Inhibitors are designed to predict the unsafe opera-tion of the truck for the operator, says Cianci. These functions automatically reduce the forward and reverse travel speed of the truck at different heights and automatically control tilt angles.
Get on the bus. The lift truck indus-try, like other mechanical solutions, is moving from preventative maintenance toward predictive maintenance. “We’re not there yet,” says Ed Campbell, sales manager for the materials handling group at Landoll Corp. “But with the CAN BUS system, we get two-way communication with the components. That lets us know whether we’re oper-ating a higher temperature, which allows us to react to something before it fails.” Hydrostatic drives. “The vast major-ity of the equipment in use today
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modern information management
12 Companies mentioned in this articleCrown, www.crown.com
doosan industrial Vehicles america, www.doosanlift.com
Jungheinrich, www.jungheinrich-lift.com/_jh/index.cfm
landoll Corporation, www.landoll.com/mhp
linde Material Handling north america, www.lmhna.com
Mitsubishi Caterpillar Forklift america, MCFA, www.mcfa.com
naCCo Materials Handling group, www.nmhg.com
nissan Forklift Corporation north america, www.nissanforklift.com
raymond, www.raymondcorp.com
toyota Material Handling Usa, www.toyotaforklift.com
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is powered conventionally with IC engines or battery power,” says Mark Roessler, general product manager for Linde Material Handling North America. “Because of that, our focus has been on optimizing those designs for the end user.” At Linde, that trans-lates into hydrostatic drives that use oil flow and pressure to accelerate and decelerate the truck in either direc-tion. “With hydrostatic drives, there
are no friction brakes, no mechanical transmissions, no drive shafts and no U joints,” says Roessler. “That allows you to eliminate the wear and tear in the drive system.”
Getting narrower in narrow aisle. As warehouses strive to get more stor-age in the same amount of space, nar-row and very narrow aisle lift trucks are key. “When we first started in this business, our trucks operated in a 7-foot aisle,” says Landoll’s Campbell. “Today, we’re operating in less than 6 feet in articulating trucks.” Part of that is attributed to redesigning the articula-tion assembly of the trucks so they are more compact and thinner to work in a narrower aisle. Another is to design a front end that can rotate 200 degrees instead of 180 degrees.
“As you’re pulling the forks out, they start to turn. That allows you to keep the forks straight until you get them out of the pallet, which makes it easier to stack in a narrow aisle,” Campbell explains. Since narrow aisle trucks are often working in high elevations,
Landoll has added a low-cost camera system to provide visibility above 25 feet as well as software that can detect and display the height elevations in every row in a warehouse.
Integrated scales. Burger King created a business out of letting customers have it their way. Toyota Material Handling U.S.A. (TMHU) sees a similar inter-est in customization among lift truck
users. “Forty percent of our orders are customized by the customer and many of those innovations turn into options that are later integrated into options on the trucks,” says Cesar Jimenez, national product planning manager for TMHU. The recently introduced integrated fork-lift scale is an example of a feature that was developed for a customer and is now a standard option on Toyota trucks. The scale, which is accurate to within half a pound and is legal for trade, allows an end user to weigh and capture the weight of a load while lifting a pal-let and loading it on a truck. In its cur-rent configuration, the system can store information about 350 loads that can be downloaded to an enterprise system. “We have the ability to add Bluetooth and Wi-Fi to automatically transmit the data,” Jimenez says.
Lithium ion batteries. Earlier this summer at CeMAT, Jungheinrich introduced a walkie for the European market powered by a small lithium ion battery the size of a brief case that can be replaced by the operator with no
special tools. “The size of the battery results in a very maneuverable truck,” says Bowles. “But, as with most new technologies, cost is the issue and at present, the cost per kilowatt hour is greater than a lead acid battery.”
A hybrid lift truck. In Japan, Toyota has introduced a true hybrid diesel truck in an 8,000-pound capacity truck. The truck operates on electric power for applications like travel, but auto-matically switches to diesel when extra power is required for an application, just like the consumer car Prius. And, like a Prius, the batteries are recharged when the truck is under diesel power. “Because you’re not consuming elec-tricity from the grid, the design has resulted in a 50% reduction in fuel con-sumption and emissions,” says Jimenez. Toyota plans to introduce a propane-based indoor cushion tire hybrid truck in North America. “Propane is the No. 1 selling fuel for us in the United States,” says Jimenez. “That’s what we’re push-ing our parent company to design.” M
“ Forty percent of our orders are customized by the customer and many of those innovations turn into options that are later integrated into options on the trucks.”
—Cesar Jimenez, national product planning manager, Toyota Material Handling U.S.A.
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A crafty slotting solution helps Creative Memories achieve more than 99.9% shipping accuracy and improve picking speed.
modern productivity solution
Creative Memories, based in St. Cloud, Minn., is a leader in the memory celebration industry,
selling premium quality photo albums, scrapbook-ing supplies, digital photo books and software.
The company markets its products at in-home parties through more than 40,000 independent sales consultants worldwide. Submitted by phone, fax or online, a consultant’s typical order contains about 10 to 20 different SKUs, which makes for a steady, high-volume flow of product through the facility.
Handling the demand is no problem. Orders flow quickly and systematically through each part of Creative Memories’ technology infrastruc-ture thanks to a fully integrated software solution
(HighJump, www.highjump.com) that includes a slotting tool.
Overall inventory management is critical, so the company added the slotting solution to its system to optimize the use of warehouse space and re-slot inventory once each month. “It’s important that fast-moving items are in the ‘golden zone’—the eas-iest location for workers to reach—to promote both efficiency and safety,” says Dan Perlinger, Creative Memories’ distribution team lead.
The system also manages the process of cycle counting to keep inventory accuracy high. “Depending on the item, it is counted either once per month, once per quarter, or once every six months,” Perlinger says. “We never do physical
Slow picking and errorS are juSt a memory
By lorie King rogers, associate editor
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modern productivity solution
inventories. Our auditors have confidence in the system.”
Creative Memories has seen measurable ben-efits from re-slotting its warehouse monthly. Before the slotting solution was in place, the company picked between 45,000 and 50,000 lines per day.
Now, it consistently picks 55,000 lines per day and achieves peaks over 140,000 lines per day.
In addition, the company’s fulfillment accuracy rate consistently exceeds 99.95%, which is instru-mental in helping the sales consultants grow their independent businesses with satisfied customers.
Slotting reapS a bumper crop of benefitSWarehouse management solution uses several slotting principles to control accuracy, production and overall pallet quality.
nature’s Best is a privately held distributor of natural and organ-
ic grocery products that supplies retailers in 11 western states. But the company’s passion for its prod-uct and growing success caused new challenges to crop up. For example, it had outgrown its distribution cen-ter, and distribution operations were reliant on an inadequate manage-ment solution.
While building a new 410,000- square-foot DC in Chino, Calif., to tackle its space issue, the company looked a supply chain solution to opti-mize operations, increase efficiency and create a distribution model that could be replicated in other regions. They chose a warehouse manage-ment solution (Manhattan Associates, www.manh.com) that offered a low cost of ownership and required minimal customization. Another benefi-cial component is a slotting feature used to manage the company’s 18,500 SKUs.
Prior to implementation, product was stored randomly within the mechanized facility that no longer fit the company’s current business model or product mix. Now, fast moving SKUs (20%) and slow moving SKUs (80%) are slotted by movement (or hits), density class and volume. Product weight is also considered from a placement perspective within the pick aisles.
Within the new configuration, the company can better control accuracy, production and overall pal-
let quality. Additionally, product damage has been reduced by 30%. And, as expected, says Jim Beck, Nature’s Best president and CEO, selection pro-ductivity has increased by as much as 10%. Safety, quality matrices and customer service, including shortages and mispicks, have also improved, Beck reports.
“Slotting has improved so much of our already improved operations,” says Beck. And, when look-ing at the overall warehouse management solution, he says, “It all paid off extremely quickly. We start-ed seeing improvement four months after imple-mentation. It usually takes three or four times that long—and I have yet to see any limits to the volume we can process.” M
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workforce metamorphosis
BY maiDa napolitano, contriButing editor
Labor cost is almost always the highest expense item in a distribution center’s budget. To control and manage this cost, visionary managers often rely on comprehensive labor management programs that promote and measure efficient methods for
performing tasks. To achieve this goal, managers tie various software tools, such as labor management systems (LMS), together with strategies to monitor, report and reward actual performance against established expectations.
These programs certainly aren’t new, and their ability to increase productivity by providing continuous feedback on worker performance is well documented. Don Cook, president of New Jersey-based labor management consult-ing firm Cook & Associates, sums it up this way: “With a good labor management program, organizations can reduce costs and ensure that merchandise is processed correctly, all while improving processing timeliness.”
According to Cook, users who are able to tie a pro-gram together with the appropriate measurement software typically report a 20% increase in productivity along with increases in work quality and reductions in service times. Cook adds that many organizations achieve payback on their investment within nine to 16 months.
Tom Kozenski, vice president of product strategy for RedPrairie—a provider of both warehouse management systems (WMS) and LMS—also points to a big modeling advantage, or the ability to test scenarios on the computer before trying it for real on the warehouse floor. “Our soft-ware can do ‘what-if ’ analyses of an operation on the com-puter and anticipate results, rather than going on the floor and trying to do ‘what-ifs’ on the fly with 100 people.”
For example, what if you consider going from picking with paper pick lists to picking with radio frequency (RF) terminals, or from RF to voice-directed systems? You can
model each alternative on your LMS and predict which one delivers the most productivity improvements before pur-chasing a single piece of equipment.
Other labor management solutions, such as those from Kronos, have also automated workforce-related processes such as hiring, time and attendance, and employee schedul-ing. Malysa O’Connor, director of Kronos’ logistics practice group, says that by automating, you gain real-time visibility into critical labor data for accurate cost accounting by cus-tomer, by order or by task.
“When you have a comprehensive system that integrates workforce business processes, you’re poised for competi-tive differentiation through the optimization of your labor resources,” says O’Connor.
Even more benefits are reported when the program incor-porates a gain-sharing, incentive-paying component. “Good workers want what they do to be acknowledged,” says Matt Kulp, director of distribution and fulfillment projects for St. Onge Company, a supply chain consulting company. “When incentive programs are done right, good workers are going to want to stay onboard.”
If you’re contemplating such a program for your organiza-tion, your timing couldn’t be better. The real-time interface of LMS with more robust WMS is giving these programs a new edge. In addition, better software, more widespread use of RF technology, and new warehouse mapping capa-bilities have reduced much of the manual effort involved in the work measurement component of the program, also increasing its accuracy.
Over the next few pages, we’ll look at labor management programs and how they span well beyond the mere installation of software. We’ll also look at what’s involved during implemen-tation and how a leading bridal products retailer is using labor management as a tool for continuous process improvements.
successful labor management goes beyond the installation of software. here’s a look at the implementation process and how one major retailer uses its program as a tool for continuous process improvements—with multi-layered benefits.
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5 things to knoW Getting the most out of your workforce depends on a sound and effective labor management program. Here are five cru-cial points to keep in mind when implementing one.
First: Strategy must be defined. Why are you doing it? Do you want to set standards for yearly budgetary plan-ning or implement an employee measurement or incentive pay system where you’re rewarding people at the individual level? “These two extremes require different levels of soft-ware, different levels of sophistication, ongoing mainte-nance, and a lot of effort and cost to implement,” says St. Onge’s Kulp. “You need to understand what you’re trying to get out of it first so you can pick the right software and pick the proper approach.”
Second: A labor management program is more than just the installation of software. “It’s a total cul-tural change,” explains Cook. “It requires thorough knowl-edge of your operations, accurate work measurement, and an effective structure of reporting that promotes feedback.”
In fact, the actual software installation itself can take 30 minutes, but many other steps must also be accomplished. Critical, labor-intensive tasks in the DC must be identified and the length of time it takes to accomplish these tasks is recorded by the actual timing of employees as they perform each task, or by using a database of pre-determined time standards. Once standards are established and the system is online, managers must be trained to coach poor performers and resolve barriers to productivity.
An incentive payment component often takes the pro-gram to the next level by rewarding good performers as part of a management plan to share the savings gained. “Incentive policies can be powerful tools because they put employees in control of their own destinies,” says Kronos’ O’Connor. “Management needs to clearly communicate expectations and put in place a consistent system that employees can trust is fair.”
Third: It’s tough to manage without software. “You could get by for a while without software in a very small organization, say 50 employees or less,” says Cook. “How-ever, you may have to employ more managers than neces-sary to try to keep track of what’s going on. In this day and age, as DCs and fulfillment centers become larger and more complex, you generally need the software because of the enormity of the data that you’ll be collecting and monitoring.”
Fourth: Expect cultural challenges. In cases of union involvement, it might be wise to get them involved from the very beginning, says Lisle Holgate, product marketing manager for RedPrairie’s workforce management platform. “Unions tend to support standardization when its members’ performance is based on a reasonable time to do the task in a safe and efficient manner.” Kozenski adds that some unions have engineers who will validate these standards as part of this process.
Fifth: Don’t install a program and proclaim you’re done. “You’re never done,” says Kozenski. “You’re always
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Components of a complete labor management system (LMS)Compon
• Punch capture
• Time-off management
• Payroll calculation
• Exception reporting
• Alerts
Time andattendance
ompnents of a co
ture
nt
culation
eporting
ndnce
• Estimate resource needs
• Time to complete activities
• Balance resources across operations
Resourceplanning allocation
manplete labor m
esource
mplete
sourcesrations
rceocation
• Measure perform- ance against standard
• Provide real-time reports
• Track quality and safety
• Track activity- based costs
Performancemanagement
ystenagement sy
erform-st
al-time
ty
ty-s
ancement
• Calculate incentives
• Integrate with payroll systems
• Observation management
• Report cards
Incentivesreward discipline
em (LMS)
centives
withems
nnt
ds
vescipline
• ROI-based slotting
• Simulation
• Process modeling
• Establish standards
• Quality management
Laboroptimization
slotting
odeling
andards
agement
ration
• Greenfield
• Facility analysis
• Continuous improvement
Slotting andsimulation
Source: RedPrairie
peeling the onion. You’re always look-ing for better ways to improve your operation.” The program must be flex-ible enough to quickly change as you change your methods and procedures. As a result, it’s imperative to keep maintenance costs in mind going for-ward. Depending on the number of employees and the number of facili-ties, one or an entire staff of engineers may be needed.
With these key points in mind, let’s see how David’s Bridal, the biggest U.S. retailer of “everything-weddings,” implemented its labor management program.
Measuring DaviD’s BriDalPlanning a wedding? Look no further than David’s Bridal, the country’s larg-est bridal retailer, offering the con-venience of one-stop shopping for wedding-related products and services from its 300 brick-and-mortar stores and its Web site.
However, Tony Coccerino, vice president of logistics and distribution, will be the first to tell you that this suc-cess would not be possible without the retailer keeping a close eye on labor costs within their two DCs in eastern Pennsylvania—a 174,000-square-foot facility in Conshohocken that employs 35 to 45 hourly associates and a newer, more automated 230,000-square-foot DC in Bristol that employs 75 to 85 hourly associates.
Back in 2001, with only the Con-shohocken DC up and running, Coccerino, says that his team was experiencing difficulties with man-
aging the growing pool of hourly associates. “There was no means of tracking what each associate was doing,” says Coccerino, “and we felt that we were bringing in more people and more temps without ever getting ahead.”
Quickly digesting the problem, management decided to implement labor standards to at least hold the associates accountable for what they do and how much they do. Along with some due diligence, and after narrow-ing the field to two potential LMS pro-viders, the retailer decided on Cook & Associates’ Productivity Evaluation Program, also known as PEP.
In May 2001, the PEP team started a multi-phased approach with David’s Bridal management group, bring-ing them up to speed on the steps to generate, use, and analyze reports that provide constructive feedback to associates. At the same time, they also started the month-long process of identifying and measuring different tasks throughout the DC, using time studies and time logs that employees were trained to fill in for certain spe-cial projects.
Once the measures and standards were established, the team then had to make sure that PEP could interface seamlessly with the retailer’s WMS (Manhattan Associates) and Kronos’ Time and Attendance System. The WMS details all the work and critical data—such as the type of task per-formed, the number of units picket, or the number of orders completed—are extracted and used as input into PEP. The Kronos system automatically pro-
vides PEP with the exact number of hours that the associate was paid to work for a given shift.
The teams then rolled out the sys-tem and introduced it to the hourly associates in September of 2001. A few more weeks of fine-tuning ensured that the standards would be correct and fair before managers started reviewing employees—identifying who was mak-ing the grade and who was going to need some coaching. A year later, man-agement decided to share productiv-ity gains by implementing a cash-back incentive program that included every-one from hourly associates to janitors to supervisors to managers.
It’s been 10 years since the first installation, and according to Coc-cerino, the benefits have been signifi-cant. “Just by introducing standards we felt that we were going to get a decent productivity improvement of 7%. We wound up getting 10% to 12%,” says Coccerino. After adding the incentive program, productivity increased another 12%. Through the program, DC manag-ers now know how long it takes to do a job, allowing them to confidently plan how much staff they need to complete future work.
Coccerino admits that the associ-ates weren’t so sure at first about the changes, thinking they were being micro-managed. “But they came onboard once they started seeing an extra $50 or $100 in their paychecks every other week—just by doing their job.” M
Maida Napolitano is a contributing editor to Modern Materials Handling
MMH1108_WDCLabor_Supp.indd 54 8/10/11 9:18 AM
Covered by one or more of the following U.S. Patents: 6,244,821; 6,589,016; 6,817,835; 6,939,108; 7,252,478; 7,284,960; D587,799; D607,988; 7,654,798 and other patents pending. ©2011 Delta T Corporation dba the Big Ass Fan Company. All rights reserved.
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Ideal for all rack and shelvingapplications, self-adhesiveSlip•Strip™ adheres to any cleansurface.
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messages slip easily through theopen edge and are held snuglyin place. Repeated label chang-ing without messy adhesivebuildup is simple! Slip•Strip™ hasa clear face for easy reading orscanning. The white backgroundprovides a neat, clean appear-
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low-level palletizer delivers fast pallet stackingThe 72AE palletizer combines the accessibility of a floor-lev-el unit with speeds associat-ed with high-level machines. By incorporating an extended accumulation table, the pal-letizer enables continuous layer forming during layer transfer and stacking, increas-ing volume up to 35 units
per minute. Features include energy-efficient electric motors as well as programmable layer patterns and pallet configurations. It can palletize cases, trays, bags or totes with automatic changeover on a touchscreen operator panel. For flexibility as new pallet, layer, and product configurations are added or modified, an intelligent control lets you independently adjust all of the operating parameters. a-B-C Packaging Machine, 800-237-5975, www.abcpackaging.com.
FOCUS ON Packaging equipment
stretch hood machine secures palletized goods with filmFor packaging palletized goods, the stretch hood machine features control technology that recognizes various stack heights for flexible, automatic adjust-ment by the machine. An ultrasonic sen-sor determines the required film length. Film is then cut and sealed along the cut edge, forming a hood that is crimped, pulled over the stack and tucked under-neath the pallet to fit snugly. Quick and efficient, the packaging process protects goods from the environment, water, dust and insects, while palletized goods are clearly visible through the transparent film. Beumer, 732-893-2800, www.beumer.com.
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mmh.com Modern Materials Handling / A u g u s t 2 0 1 1 57
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Slip•Strip™ features a uniquebottom-loading design. Barcodes, price displays, signs and
messages slip easily through theopen edge and are held snuglyin place. Repeated label chang-ing without messy adhesivebuildup is simple! Slip•Strip™ hasa clear face for easy reading orscanning. The white backgroundprovides a neat, clean appear-
ance. It can be used in its full36" or 48" length or easilyscissor-cut to size. Six standardwidths accommodate labels from3/4" to 3" high. Package quanti-ties are 6 or 24. Magnetic orhook/loop backings, color orcustom-imprinted backgrounds
Now from Aigner: Slip•Strip™, theMost Versatile Label-HoldingSystem.
are optional. For samples andmore information, callfor our catalog andnearest distributor.
Aigner Index, Inc.218 MacArthur AvenueNew Windsor, New York 12553Tel: 1.800.242.3919 Fax: [email protected] www.aignerindex.com
Formerly CEL-U-DEX Corporation
automate your load transfer Capable of transferring products packaged in cases, barrels, drums, bags and pails from one pallet type to another, the Load Transfer Station with Pallet Cart (LTS-C) allows a lift truck driver to place the “go to” pallet onto a pallet cart for automatic pro-cessing. The system works with standard size plastic and wood pallets used in receiving and shipping applications. The sys-tem reduces warehouse worker injuries, streamlines plant and warehouse operations, improves plant and process cleanliness, and reduces handling costs. It may be used as a stand-alone machine or can be fully inte-grated with automatic pallet washing and/or stretch wrapping. Columbia Machine, 360-694-1501, www.palletizing.com, www.loadtrans-fer.net.
affordable picture frame pallet reusable, recyclableCombining strength and economy in lightweight one-piece construction, the 48 x 40-inch RACX pallet is fabricated of recycled HDPE plastics for repeated use. The pallet fea-tures a picture frame bottom and runners on all four sides for added stability, making it ideal for use with warehouse racking systems, stack loading, closed-loop transport, floor storage and automated materials handling applications. Engineered so that the bottom pallet can handle the full static load when loaded pallets are stacked two or more high, the pallet offers unsupported rack capacities up to 2,200 pounds. Static load capacities are rated to 25,000 pounds; dynamic loads to 5,000 pounds. decade Products, 616-975-4965, www.decadeproducts.com.
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New High Performance B55AC
LANDOLL CORPORATIONMATERIAL HANDLING PRODUCT DIVISION
1900 North Street · Marysville, KS 66508 · 785-562-5381 · Fax [email protected] . 800-428-5655 · WWW.LANDOLL.COM/MHP
New High Performance B55AC
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FOCUS ON Packaging equipment
Stretch wrapper uses oversized film for higher outputUsing oversized film rolls measuring 3.28 feet (1 meter), the Silkworm stretch wrapping machine simplifies the end-of-line process with higher output and greater film efficiencies. The film is twice as wide as typically used film, reducing rotations by half to effectively wrap a pallet. The film width ensures a high level of adhesion during application and greater stability for the pallet throughout storage and transport. Features include a rotating table and one or two wrapping robots for output rates from 110 to 165 pallets per hour. Elettric 80, 847-329-7717, us.elettric80.com.
Corrugated plastic containers in 6,000 sizesA versatile line of corrugated plastic containers is offered in more than 6,000 sizes and 20 styles. Durable and lightweight, the containers may be cus-tomized by color or shape to accommodate contents. Styles include hopper front dividable, stackable hopper front, straight wall dividable, nestable, hori-zontal carousel and heavy duty stackable. To protect products and maximize storage density,
partitions and custom foam cushioning may be specified. For shipping of static sensitive products, electrostatic dis-charge safe materials can be used in construction. Flexcon Container, 908-871-7000, www.flexcontainer.com.
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www.interlakemecalux.com
We Manufacture Warehouse Solutions
Seal up to 40 cases per minuteIdeal for high-speed operation up to 40 cases per minute, the EZGlue case sealer glues and seals erected and loaded cases in a compact footprint. The system incorporates a flight bar to ensure that each case is square prior to sealing, making it perfect for tall cases that tend to tip on a belt conveyor, or for light or heavy cases that require a positive push through the machine. Features include a heavy-duty, welded steel frame base, a trouble-free mechanical chain drive system and Omron PLC with touchscreen user interface for full access to all machine functions. To enhance safety, the system is equipped with interlocked gates and doors, and low control voltage. Eagle Packaging Machinery, 305-622-4070, www.eaglepm.com.
High-speed robot palletizes up to 1,900 cycles per hour
Well-suited for high-volume production in bag and box palletizing operations, the M-410iB/140H palletizing robot handles a 308.6-pound payload. Its slim arm and wrist feature integrated cable routing to minimize interference with tooling and other periph-eral devices, while its compact size allows it
to work in small spaces with low ceiling heights. An intelligent device, the robot uses 2D bar code reading to adjust its end-of-arm tool to match the size of each case to be handled, as well as an integrated auxiliary axis that coordinates gripping force and case placement. The robot performs 1,900 standard palletizing cycles an hour—one cycle in less than 2 seconds. Fanuc Robotics America, 800-477-6268, www.fanucrobotics.com.
Reusable pallet for grocery industry The 40 x 48 x 6-inch TS reusable plastic pal-let is ideal for storage, shipping and handling of products distributed throughout the grocery supply chain. Nestable, the pallet optimizes space by fitting 1,260 pallets in standard 53-foot trailers. Its anti-skid surface holds cases and boxes in place in transit and at retail. For easy handling and durability, it features four-way hand and fork truck entry, contoured corners and surfaces, and smooth, non-porous construction (without nails, rust or splinters). The pallet’s all-plastic construction does not absorb moisture or odor while ensuring dimensional consistency and repeatable performance. ORBIS, 888-307-2185, www.orbiscorporation.com.
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FOCUS ON Packaging equipment
Special containers protect produceThree new reusable plastic containers handle bananas, eggs and strawberries. Specially configured to protect these perishables during transport from farm to store, the ergonomic contain-ers reduce shrink and enhance handling. The RPC for bananas provides faster cooling and better temperature management for fruit ripening and freshness at retail display. The strawberry container meets the industry-standard, 60 x 40-centimeter footprint, delivering a cross-stackable pack of nine 1-pound clamshells for a 9% increase in clamshells per pallet versus con-ventional corrugated pack. For fresh egg producers, the egg container improves protection and quality from source to con-sumers by reducing breakage shrink by more than half. IFCO, 813-463-4124, www.ifcosystems.com.
Conventional in-line palletizer incorporates robotic armsPackaged with a combina-tion of a conventional in-line palletizer and a robot-ic arm for pattern forming
in single- and multi-line applications, the Alvey 950 series pal-letizer is ideal for handling small finished case sizes, multiple product formats and complex patterns. The system uses one or more jointed-arm robots for pattern forming, coupled with flex-ible programming capability with the human machine interface. This design permits fast and easy product reconfiguration and quick line changeovers at packaging rates of more than 100 cases per minute. Gentle product manipulation accommodates a reduction in secondary packaging without compromising fin-ished product integrity. Intelligrated, 877-315-3400, www.intelligrated.com.
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We’ll handle it.
www.bulkpak.com
With bulk containers, one size doesn’t fit all. ORBIS BulkPak® offers the largest selection of bulk containers in the industry, and the solutions you need for any application, from industrial, food and beverage to storage and distribution. And if we don’t have it, we’ll fabricate it just for you.
How do we offer unbiased bulk container solutions for all types of applications?
Part bin for work-in-process useIdeal for work-in-process, the PB104-4 part bin measures 10 x 4 x 4 inches. It provides secure storage of parts and product in assembly operations, warehouse and hardware merchandising applications. The bin is compatible with several of the supplier’s metal storage systems, including rail and louvered panel floor stands, wall-mounted units and bench assemblies; shelf systems; metal cabinets; bin carts and wire shelving. Manufactured of polypropylene to resist water, rust and cor-rosion, the bin may be specified in six colors (red, dark blue, yellow, green, stone and clear) for organization. A molded-in label area on the front of accommodates bar code placement or identification label. LewisBins+, 877-975-3947, www.lewisbins.com.
Kit prevents washing machine damageTo ensure load stabilization and prevent drum damage when moving residential and commercial grade front and top loading washing machines, the Litkit is an alternative to bolting the drum in place during transit. The system is less expensive than drum protection kits sold by wash-ing machine manufacturers. Quick and easy to install, the reusable Litkit system works with all makes and models and accommodates older machines that have no OEM-designed stabilization kit. Litco International, 330-539-5433, www.litco.com.
Void-fill packaging foam Featuring plant-based, renewable materials, Instapak RC45 foam is easy to use and ideal for light-duty packaging applications. The foam includes 25% renewable content, reducing the use of petroleum-based raw materials. It is com-
patible with the supplier’s Instapak foam packaging systems, and is shipped and stored as highly concentrated liquid prod-uct. When the two liquid components are mixed (on-site and on-demand), the resulting foam is used to create form-fitting pads that provide cushioning, blocking, bracing and void-fill protection. Sealed Air, 800-648-9093, www.sealedair.com, www.instapak.com.
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FOCUS ON Packaging equipment
Affordable, semi-automatic stretch wrapping machine
The Sentry semi-automatic stretch wrapping machine unitizes pallet loads weighing up to 4,000 pounds. Capable of handling a maximum load size of 52 x 52 x 48 inches, the unit features a low profile turntable that can be loaded with a forklift or by pallet jack (with an optional ramp). With a maximum speed of 12 rotations per minute, approximately 20 to 30 loads per hour can be unitized. The 20-inch stretch film is elongated through a powered prestretch film carriage for a stretch ratio of 200% to maximize film strength and decrease film usage. The machine also integrates a vari-able carriage speed, automatic load height sensing, home position alignment, separate adjustments for top and bottom wraps and a user-friendly, multi-lingual control panel. Orion Packaging Systems, 800-333-6556, www.orionpackaging.com.
Mobile pallet wrapper includes pallet jackOffered as an alternative to conventional handheld stretch wrapping, the GW-3500 mobile pallet wrapper is portable and includes a pallet jack for improved productivity, con-sistently wrapped loads, elimination of wasted film and a reduction in worker injuries. The wrapper han-dles 70-inch diagonal loads, wrapping 10 loads per hour while running at 11 revolu-tions per minute. Features include manually adjust-able film tension, up/down wrapping cycles, independent top and bottom wrap pattern selection from one to nine wraps and a splash-proof wrapping mode. GaleWrap, 866-425-3727, www.galewrap.com.
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mmh.com MODERN MATERIALS HANDLING / A U G U S T 2 0 1 1 63
To schedule a supply chain analysis today, please visit www.bulkpak.com or call 888-217-0965.
We’ll handle it.
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With industry leading expertise, innovation, high quality products and lowest total cost of ownership, it’s easy to see why ORBIS BulkPak is the leading choice for bulk containers in the industry. You get more out of BulkPak, because we put more into it.
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With industry leading expertise, innovation, high quality products and lowest total cost of ownership, it’s easy to see why ORBIS BulkPak is the leading choice for bulk containers in the industry. You get more out of BulkPak, because
We put more
Extra-long bin for pallet rack storageThe 42-inch long Rackbin extra large storage bins fit pallet rack to store larger items without wasted space. Ideal for easy organization of inventory, the heavy-duty bins are made of polypropylene, making them waterproof and corrosion free. The bins may be specified in three widths and two colors—blue and gray. For easy handling, the bins include heavy-duty front, back and side grips, and a wide stacking ledge and anti-slide lock that keeps stacked bins steady by preventing forward shifting. Each bin has a pattern on the bottom for eight, 0.25-inch drill holes for easy insertion of openings for drainage and air circulation as needed. Quantum Storage Systems, 800-685-4665, www.quantumstorage.com.
Hybrid air-pillow cushioning system The AirSpeed hybrid cushioning (HC) Versa machine produces cushioning in three different widths: 24, 18 and 12 inches. The unit can produce 0.75-, 1- and 1.25-inch cell heights with a typical perforation preset of every 6 or 12 inches. As air is transferred between the individual chambers of the film, rows of small air-filled pockets are created. The system handles multiple roll widths up to 32 inches on a dispenser head that is 60% smaller than previous models, and uses HC-Flex high performance low-density polyethylene air pillow film made with 30% less resin than alternatives. Flat, perforated rollstock is mounted onto the unit externally for placement flex-ibility and space savings. Pregis, 877-692-6163, www.pregis.com.
Extruded plastic slip sheets, dividers offered Aline of extruded plastic sheet products—including slip sheets, divider sheets and pallet pads—is made from 100% recyclable materials. The slip sheet is offered as an alternative to wood pallets and corrugated sheets for one-way shipments. It is engi-neered to reduce tab failures and have a higher coefficient of fric-tion than comparable sheets. Each weighs 2 pounds and requires minimal space in a trailer or container, allowing shipment of more products while improving sanitation, saving warehouse space and reducing the cost of each unit load. Manufactured with recycled HDPE resin, the sheets come in standard or custom sizes. Rehrig Pacific, 800-421-6244 www.rehrigpacific.com.
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64 A u g u s t 2 0 1 1 / Modern Materials Handling mmh.com
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FOCUS ON Packaging equipment
Paper-based honeycomb pallets offer branding surfacesThe all-paper, honeycomb-based Billboard pallet features an outer edge wrap of kraft paper layers laminated to a clay-coated (white) outer surface onto which logos, brands or store names can be printed in a repeating pattern. Ideal for use with products sold in warehouse stores, where items are stacked several pallets high and the product may be obscured by stretch wrap, the pallet edge is still exposed. The pallets con-tain 80% virgin fibers and wrapped fiberboard feet for water resistance. Each weighs approximately 8 to 10 pounds, and handles static loads up to 6,000 pounds. Pregis Hexacomb, 877-692-6163, www.hexacomb.com.
system produces 960,000 nestable, plastic pallets per yearThe Pallateer #4 plastic pallet making system is a fully auto-mated production cell employing dual, stack mold technology with four cavities. With a 6-inch extruder capable of melt-ing 2,400 pounds of resin per hour, the system can produce 960,000 nestable, one-way 48 x 48-inch pallets annually. The machine includes a top entry stacking robot, blender, loaders, nitrogen gas generator, mold cooling water chiller and two stack type dual cavity aluminum molds with support beam. Compact, the entire unit fits in a footprint of 47.6 x 16.4 feet. Wilmington Machinery, 910-452-5090, www.wilmingtonma-chinery.com.
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www.interlakemecalux.com
We Manufacture Warehouse Solutions
High-speed robotic palletizer with short movementsFor high-speed palletizing applications in minimal floor space, the iP robotic pal-letizer is equipped with a Fanuc articulated arm robot. The high-level palletizer is integrated with an automatic pallet lift and product collation system to handle products at high speeds, 24/7, and in harsh environments. The palletizer pre-cisely places cased and bagged products into highly stable loads. Auto indexing minimizes the motion required by the robot while maximizing speed, efficiency, cost and labor savings. The machine may be configured with dual station 1-in-2-out or with a single station 1-in-1-out setup; both are fully automated with pallet transport conveyor, pallet dispensing, and slip sheet dispensing. Schneider Packaging Equipment, 315-676-3035, www.schneiderequip.com.
On-demand cushion film is curbside recyclableProduced on-demand using ambient air, AIRplus cushion film eliminates the inventory and handling issues associated with pre-made bubble products. The flexible material is formed on simple-to-use machinery that occupies a small foot-
print for space savings. It uses triple layer film to cushion and protect, or to serve as void fill, and is curbside recyclable. Ideal for wrapping consumer electron-ics, glass, ceramics, CDs and DVDs, the flexible wrap includes perforations for easy separation. Storopack, 800-827-7225, www.storopack.com.
Inflatable, flexible packaging protects irregularly shaped productsThe customizable O3 Flex packaging system prevents product damage by surrounding the entire surface of the product with air tubes. Ideal for irregular shapes, the packaging wraps around and protects irregular products and surfaces. Made from multi-layered polyethylene strengthened with nylon, each of the tubes of air is isolated from surrounding tubes, ensuring that if one is deflated the rest remain inflated. The moisture resistant material is transparent for full visibility of contents and is 100% recyclable. Valtego, +852 2559 9413, www.valtego.com.
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Container handles biohazards safelyCertified to the UN 11H2 standard for safe transport of hazardous materials, the P-433 Ship Shape biohazard bulk container includes a seal-tight plastic cover and closure to ensure materials in transport remain inside, even if flipped over, rotated or dropped. Rotationally molded in a single piece from 100% polyethylene, the hazmat container resists chemical attack, cleans easily and accommodates a variety of plastic lin-ers. It holds up to 700 pounds on a 44 x 44-inch footprint with four-way lift access, stacks and nests, and features permanently molded-in biohazard warning labels. Meese orbitron dunne, 800-829-4535, www.shipshapecontainers.com.
FOCUS ON Packaging equipment
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robotic palletizer handles bags, cases, pailsFeaturing a payload capacity of 440 pounds and a palletizing capacity of 1,600 cycles per hour, the EC-201 pal-letizes bags, cases, pails and other products. It incorporates four axes for maximum flexibility. The weight of the mechanically balanced arm can be supported by a single finger, enabling the machine to use less energy and reducing stress on joints, bearings, pivot points and floor supports. For changing palletizing programs in less than 5 seconds, a standard touchscreen is included. The screen also displays onboard warnings, error occurrences, real-time input and output tracking, inventory tracking by specific programs, and comparison of running and powered up hours. american-newlong, 317-787-9421, www.american-newlong.com.
To advertise, or for more information please contact: Jennifer Drevline, 847-223-5225, ext. 11, [email protected]
MMH1108_FocusOn_Prods.indd 66 8/10/11 9:16 AM
modern 60 Seconds with...
Jeff Rufener TiTle: President of the Industrial Truck Association (ITA); vice presi-dent of marketing for Mitsubishi Caterpillar Forklift America (MCFA)
Web siTe: www.indtrk.org; www.mcfa.com
experience: More than 30 years in sales and marketing; nearing the end of a two-year term as president of ITA.
DuTies: To represent the interests of the manufacturers who comprise the lift truck industries, including marketing, engineering and regula-tory areas, and trade-related issues.
beverage tend to be more resilient and they buy electric trucks. That said, I think there are some factors at work that suggest the trend is more long lasting. For example, in 2005, about 55% of the industry’s orders were electric. In 2009, it was 69%. The percentage has pulled back a little this year, but the cost of fossil fuel is going up, there is increased concern of the environmental impact of fossil fuels, and we’re seeing improvements in electric technology. That’s why I think it’s a permanent trend and not connected to the economic cycle.
Modern: Fuel cells have received a lot of attention lately. Are they viable
today and what are the promise and limitations of fuel cells?
rufener: When it comes to fuel cells, there are differing opinions in the industry. From a technical standpoint, fuel cell technology has proved itself. For that reason, I think fuel cells of some sort will be a part of the landscape in the future. However, that will be further out than the next few years. Commercialization has to occur and be independent of government support. Right now, the hydrogen fuel cell industry can’t sustain itself. The fuel infrastructure also has a long way to go; yes the technology works, but getting hydrogen to a facility can be an issue. That’s a part of this puzzle that has to be solved as well. M
Modern: The lift truck industry was hard hit during the recession, but 2010 was “wow.” How do things look in 2011?
rufener: We were up 40% in 2010 over 2009, and so far for 2011 we’re 35% better than last year. That’s a marked difference from 2009, when we were down about 50% from our peak. We’re a capital goods industry and business stopped that type of spending in 2009. A strong recovery in the manufacturing sector has lead the return to spending for now.
Modern: We understand there’s been a surge in the purchase of electric trucks. What’s driving that trend?
rufener: Over the last five years there has been a significant shift in the types of lift trucks sold toward electric. Some of that has been the result of the economy. It’s pretty common to see a shift toward electric trucks during a downturn. That’s because larger companies tend to use electric and they tend to weather downturns better than smaller companies because they remain committed to capital investment plans. Also, industries like food and
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A U T O M A T I O NThe Intelligent Material Handling Company
S A P I E N T
Call or Email For A FREE Space & Productivity Analysis Today!
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New Viper VLMSmall Parts, Items and Inventory Vertical Lift Module
AS/RS Technology Taken To The Next Level…
Imagine being able to dramatically improve overallefficiencies and profitability while reducing labor andspace costs. Take your Lean and Sustainable programsto the next level by incorporating the Viper™ VLMsimple automated solutions...over a weekend.
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Available Height
Typical Floor Space SavingsElimated Bays
of ShelvingSpace
Savings
15’
25’
35’
30-36
58-66
86-95
76%
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Fewer Moving Parts Help Assure
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ViperTilt
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