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4 September 2022 Material Handling Network www.MHNetwork.com SEPTEMBER 2022 VOL. 41 NO. 8 6 Cover Story By: EU Automation Lean manufacturing losing pulling power 10 Safety First By: ASSP Survey uncovers key findings on falls from height 12 Chain Reaction By: Bill Denbigh Scope, Complexity and Cost: Calibrating Your Warehouse Automation Strategy 16 Business Management By: Kate Zabriskie Getting On-the-Job Training Right: Four strategies to start using now 18 Industry News 20 People News 21 SalesLeads 22 Product Showcase 24 Marketplace 26 Advertiser Index Don't miss our next issue: Overhead Handling - How to Keep Your Warehouse Productive Deadline: Thursday, September 15th INFORMATIONCONTACT KipAccountKradyExecutive 563 557-4493 kip.krady@MHNetwork.com. Nikole Hoffman Production Lead, Graphic Design EricGraphicFaramusDesign Have some news to share with Network readers? Email a word doc and JPG photo when networkeditorial@MHNetwork.comavailableTOSUBSCRIBETOMATERIALHANDLINGNETWORKVISITUSATwww. MHNetwork.com Material Handling Network (ISSN #21551685) is published monthly serving the material handling industry. Editorial opinion expressed herein are the authors and do not necessarily reflect the opinion of Material Handling Network. Material Handling Network assumes no responsibility for inaccuracies, errors or advertising content and reserves the right to reject or cancel any advertising for any reason, at any time.
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The new approach is required to ensure a steady supply According to Opportimes.com, a strong rebound in global demand, supply disruptions, and depletion of inventories have driven up raw material prices and transportation costs around the world — especially in North America. An increase in the price of raw materials, coupled with increasing uncertainty in manufacturing supply chains, has led many to rethink their stock management. Here, Claudia Jarrett, US country manager at industrial parts supplier EU Automation, explains why plant managers should consider alternatives to lean manufacturing.
Lean manufacturing, which was previously coined as just-in-time (JIT) manufacturing, was originally developed by Toyota in 1970. It is a production method designed to help reduce production time while reducing response times to customers and suppliers. JIT also encourages manufacturers to order parts only when needed, as close as possible to the point of assembly, so there is minimal stock held in inventory. Simply put, the strategy aims to increase efficiency by eliminating waste, optimizing processes, and cutting costs. This is achieved by producing only what is in demand and not overstocking. By reducing the production time, the method improves the productivity rate and helps increase profits. In turn, lean manufacturing has been a popular method for manufacturers to ensure products are received only at the time needed, saving space in their inventories and reducing time in the production cycle.
The current landscape COVID-19 exposed problems in lean manufacturing that have caused manufacturers to reconsider this methodology. JIT is built on forecast demand which, while reliable in the past, has now become more unpredictable. This is because the forecast is based on historical data, but unpredictable social and political upheavals, such as the national lockdowns and conflict in Ukraine, mean that this data can no longer be relied on to the same extent. However, there are a few strategies to prevent stockouts even given the current levels of uncertainty over the future.
Manufacturers are now after alternatives to ensure components are in continuous supply. Conventional approaches, such as just-in-case (JIC), where manufacturers create a stockpile of components, also provide their own set of challenges. Businesses are instead wanting a middle ground, which offers reliability without reducing profits.Asolution is moving to nearshoring or reshoring. A supplier closer to production can significantly lower replenishment times and deliver parts faster at times of need. The issue of shipping parts has always hindered faster cycle times while relying on suppliers overseas can add shipping time and coordination complexity.
Cover Story
Lean manufacturing losing pulling power
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Manufacturers can also implement a supply chain that operates on a global level, but also adapts to local demand. This is what we call a “glocal” supply chain. Companies like EU Automation rely on a reliable network of global suppliers and work with international sales experts, that speak more than 20 languages, to overcome linguistic and cultural barriers. Operating from four different locations — including the US — we offer manufacturers both the knowledge of global demand and local markets to ensure the right quantity of stock is delivered on time.
We are now living in an era where alternative approaches must be considered for a steady supply, with the reality being that supply chain difficulties and component shortages will likely persist for some time. Therefore, it is essential for manufacturers to adapt their stock management to avoid downtime and reduce delays — and consider the benefits of alternative approaches.
New methodology By offering visibility over production, newer automation technologies can also help manufacturers decrease lead times and stay afloat during unexpected events. This provides manufacturers with the ability to target specific areas of production that need improving. Moreover, a warehouse offers insight into waste and consumption rates. Automated replenishment ensures businesses can manage warehouse assets. Automated devices identify components in short supply, before automatically reordering them from the distributor. This helps production managers to cope with demand, without worrying about component
are likely to affect manufacturing for many months to come, and while manufacturers enjoyed the benefits of JIT production and lean manufacturing for many years, times have changed.
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Six key findings surfaced from the 671 responses to the Fall Experience Survey:
Survey uncovers key findings on falls from height
2. Lack of planning is associated with a lower likelihood of using fall protection. The odds of using fall protection were 71 percent lower for individuals whose employer failed to plan.
The ANSI/ASSP Z359 Fall Protection and Fall Restraint Committee will use the key findings from the Fall Experience Survey – which explored the root causes of falls from height – to enhance voluntary national consensus standards that guide safety at construction sites and many other workplaces.“Whiledata has been available on the types and rates of fatal and non-fatal falls, we need more information on the causes of those falls,” said Thomas Kramer, P.E., CSP, chair of the Z359 committee. “These new insights expand our knowledge so we can strengthen standards and ultimately prevent injuries and save lives.”
ASSP is the secretariat of the Z359 committee that develops voluntary national consensus standards to address fall protection equipment and systems for climbing, work positioning, fall arrest, rescue, evacuation, and other fall hazards.
Falls are the leading cause of death among construction workers. Despite the efforts of safety and health professionals to increase the use of fall protection, 368 construction workers and 805 workers across all industries died from falls in 2020, according to the U.S. Bureau of Labor Statistics. Fall protection in construction has remained the most frequently cited OSHA violation each year since 2011.
The 20-page preliminary report published this month by CPWR provides an overview of the main survey findings, and additional reports with further analyses are planned. “It’s important to remember that all falls are preventable, and that drives us to collect better information that can foster operational solutions,” said Jessica Bunting, MPH, director of CPWR’s Research to Practice (r2p). “Our new data is directly from people who are knowledgeable about workplace environments where falls are common.”
3. Nearly half of respondents (48.8 percent) said no fall protection was being used at the time of a fall.4. Employee beliefs about their company’s fall protection policy are strongly associated with their use of fall protection. Respondents who thought fall protection was required were eight times more likely to use it.
Working at height is inherently hazardous, exposing workers to significant risks that range from falls from roofs, scaffolding, and ladders to slips through floor and roof openings. And the lack of use of personal protective equipment – and its misuse at times – greatly increases those risks.
10 September 2022 Material Handling Network www.MHNetwork.com
Safety
1. Respondents believe a lack of planning is a key underlying cause of falls. Insufficient or ineffective planning was the most selected primary cause for falls (27.4 percent).
A survey conducted last year by CPWR – The Center for Construction Research and Training, supported by the American Society of Safety Professionals (ASSP), gathered insights from safety and health professionals that will help advance fall protection in all industries worldwide.
5. Rescue training may help reduce fall-related deaths. The odds of a fall being fatal were 76 percent lower for workers who had self-rescue training.6.Workers employed by subcontractors face a higher risk of fatal falls. Those who work for a subcontractor were 2.7 times more likely to die from a fall compared to those who work for a general contractor.
First
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Sortation systems identify items on a conveyor system and divert the products or packages to specific destinations. These systems are often used to route or sort items and packages to carrierspecific cages or doors for shipping but can be far more elaborate in their complexity. Stations in automated conveyor systems can include:
• Inserting packaging material.
There are key issues that must be mentioned in both light and voice picking. The amount of data that can be presented or collected is, by the nature of the technology, very limited. “Pick this many” and “did you pick them” are simple binary types of responses and both light and voice picking suit this kind of function well. As the conversation gets more complex, the user’s ability to direct the Chain Reaction
Commonly used for transportation of inventory and packages without adding labor, they are simple to install and operate and are often combined with other forms of automation. While inflexible and often expensive to build, they usually have a low running cost and a limited technology stack. While this is the least glamorous of modern warehouse automation, it is still the most common and often forms the backbone of warehouse automation solutions.
Historians believe that the Greeks changed the direction of writing from right to left or top to bottom to the western style of left to right to accommodate the limitations of the innovative reed pen, which snagged the fibers of papyrus. Imagine that; the newest technology of the time fueled fundamental changes to the way we conduct business today. Innovation often comes in waves, and warehouse automation is reaching a crest. And so, as new tools — and new limitations — flow into modern warehousing, it is important to consider the innovations on the horizon that will help you meet your labor challenges, customer demands, and organizational goals.
• Adding the final destination, often courier specific, to the container.
• Order wrapping. Used to stabilize items in shipping.
Pick/Put Systems
Traditional Warehouse Automation: Conveyors, Divertors, and Sorters
• Order pack check. Using weight check, image recognition, RFID, or other technologies.
• Weight and ship. Preparing the order for transportation by a common carrier.
Pick-to-light systems employ alphanumeric displays and buttons at storage locations to guide employees in light-aided manual picking, putting, and sorting of packages or products. These light buttons and displays often have colors and numbers to highlight quantities and unit-ofmeasure instructions for the items being picked. Voice-picking systems augment the normal visual prompts with audible voice prompts and capture activity via voice responses. Both light and voice picking has the ability to free up the hands of the picker to make their workflow more efficient and, in the right application, can significantly reduce friction in the picking process.
We have seen a recent explosion of demand for automation in the warehouse, from curiosity to major infrastructure investment. Indeed, there are several types of warehouse automation systems now in existence, each varying greatly in scope, complexity, and cost. Yet many logistics leaders are struggling with the starting point for their automation journey; so to help, I've put together this overview of the four key types of automation, how they work and for what use cases they are generally best suited.
• Box assembly. Building shipping containers around the items in the order.
Scope, Complexity and Cost: Calibrating Your Warehouse Automation Strategy
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When looking at GTP systems, it is important to consider initial capital cost, since they can be very expensive to set up and implement. Also important is the realization that you are building a system with a single point of failure; if there are maintenance issues once implemented, there is no reverting back to manually picking. Keeping GTP systems well maintained and running smoothly is, therefore, a vital part of this form of automation. These systems have many forms, but include:
Chain Reaction continued Milwaukee,
pick to voice is used for highvolume case picking in retail or grocery while pick and put to light are used for small parts in high-volume order fulfillment, and where picking items are more prone to error, such as for cosmetics or shoes. Used in conjunction with the right application, these solutions can be amazing upgrades to warehouse efficiency and accuracy. Word of warning, however: These systems are not panaceas and there are legions of failures where the application and problem these systems are trying to solve simply do not match the solution.
Goods-to-person Systems Goods-to-person (GTP) systems store products within the system and automatically transport the goods directly to the operator as needed for picking, thus eliminating picker travel time. These systems are increasingly used to eliminate labor costs in high-volume picking scenarios and provide very high-speed and accurate picking processes.
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workflow becomes more and more difficult — until simply using a scanner and RF terminal is more effective. Applications from pick/put systems should be very simple and repetitive in nature for them to be successful and when considering the application this should be primary in the evaluation.Mostcommonly,
• Carousel (vertical and horizontal). These are similar yet simpler versions of ASRS systems with bins attached to a spinning carousel. The system or operator enters the pick list into the system and the system presents the appropriate bin to the operator for picking.
• High-density, small, and light goods picking is often used in grocery and e-commerce, ASRS systems may run from a bin-based or shuttlebased process where goods are stored and retrieved inside a very dense cassette of storage bins.
• Vertical lift modules. These are built where there is sufficient height in the building to take advantage of the system. They can manage heavier goods than ASRS and carousels and may often be used for not just picking but order consolidation and parts buffering in the warehouse. These systems may be best employed where picking is one part of the entire order value-added process, which requires rework and processing for orders prior to being shipped.
Most commonly, goods-to-person automation is used for e-commerce fulfillment, high-volume single-piece picking, and high-volume picking in a market where there are tight labor conditions.
Robot Systems Warehouse robots are used for either transporting goods — often automated lift trucks to heavy load carriers — or to assist in picking, packing, sorting, WI USA • docklite@phoenixlighting.com
There are two basic robotic automation picking processes. The first involves robots that come to a picker who picks inside a zone and marries up goods from a picking bin to the robot then moves onto the next zone for more of the order; alternately, the other process involves a robot that can bring racks or bins to the picker in a semi-GTP process. Both are effective in their own application and some warehouses may need both to maximize the potential of robot automation.
Though, as you can see there is no ‘one automation fixes all my problems’ answer, and most warehouses will end up with more than one type of automation to address the specific problems found in their specific environment. In next month’s article, I will be discussing how to start the journey to automation and how to make the various automation technologies work together effectively.
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Robots are still being used predominantly by early technology adopters in the warehouse; these include 3PLs needing picking flexibility and organizations that need automation but resist adding significant infrastructure changes. In addition, warehouses that face heavy seasonality and order volatility are investigating robots since they can be added and removed as needs fluctuate.
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There’s No ‘Easy’ Button
Bill Denbigh serves as the vice president of product marketing at Tecsys. Bill started working in supply chain software some 30 years ago; his entire career has been laser-focused on designing and building pragmatic supply chain solutions that address the real problems that customers are facing in their supply chain operations. (877) 621-5438
As an automation-agnostic supply chain software provider, I often hear that a silver bullet for automation would be a very welcome alternative to the hundreds of technologies emerging today.
www.MHNetwork.com Material Handling Network September 2022 15
Chain Reaction continued and storing goods. These robots can perform tasks in an automated manner or collaboratively work with existing warehouse material handlers. They are usually added to the existing warehouse infrastructure, require the least modification of a warehouse design to implement, and often demand the least initial capital cost.
Despite our best efforts, it’s not as easy as it looks to get the training equation right. We train too early, we train too much, or we make a host of other errors. While some of us learn from our mistakes, many of us practice a cycle of rinse and repeat as we make the same blunders year after year. The good news is it doesn’t have to be this way. With some careful planning and followthrough, you can avoid problems many people will encounter again and again.
Strategy Two: Connect to Why Again and Again When people don’t know why they are doing something, they don’t understand the big picture. While they get the process at a surface level, their limited understanding potentially keeps them from following procedures later. For example, if someone is learning how to use a printer/copier/scanner/fax machine and part of the process is putting the guard up on the paper tray with jobs over 100 sheets, without explaining why that’s important to do, that learner might take it upon himself to skip that step back on the job. Only when papers are scattered all over the floor and have to be re-collated does the learner know the importance of raising the guard.
Strategy One: Keep Training Relevant and Immediately Applicable
Getting On-the-Job Training Right: Four strategies to start using now
Strategy Three: Use Multiple Channels to Cement Learning
• “I learned so much during orientation. It’s too bad I won’t use most of it for six months. I took some notes, but I’m sure I won’t remember half of what they told me to do.”
I showed her how to do it, she did it, and now she’s trained. Maybe that’s true for the simple stuff, but for the complex processes and procedures, multi-channel encoding reigns supreme.
Good training designers know the value of careful pacing, and they practice just-in-time training when they can. Ask yourself, what does my learner need to be successful on the first day, the first week, and the first month? Teach those needs as much as possible, and save the more in-depth information for a more appropriate time. What do you need to prioritize?
The multi-channel approach allows learners to see, to hear, to write, to speak, and to do whatever process they are learning. Depending on
• “I’m overwhelmed. I learned a new piece of equipment today. The person showing me what to do knew everything. The problem I had was the deep dives. He spent so much time on troubleshooting techniques. It was just too much for my first day.”
For example, show learners in real-time how to complete a process. Then do it again, at the same time providing a narration track while the learner takes notes. Next, have the learner read aloud the notes she’s taken. Finally, have the learner demonstrate the procedure.
Countless onboarding programs attempt to teach everything a person would ever want to know or need to know about a job in the first few hours, days, or weeks. The information is essential, but it has no immediate value. Subsequently, learners become overwhelmed in class, and then they don’t have opportunities to apply or reinforce what they’ve learned for months or even years.
16 September 2022 Material Handling Network www.MHNetwork.com Business Management
• “I can follow the steps, but I have no idea why I’m doing what I’m doing. I sort of feel like a trained monkey. I hope nothing goes wrong because I will have no clue how to fix it if something does.”
Great trainers make connections. They repeatedly explain why they’re doing what they’re doing, why procedures are written as they are, and so forth. Are you connecting the dots as well as you should, or could you do a better job?
It’s one thing to conquer a task during class or one-on-one job coaching, but it’s entirely another to reproduce those results on the job.
www.MHNetwork.com Material Handling Network September 2022 17
Business Management continued the learner, some senses may be more powerful than others. And in rare cases where there is no preference, repetition wins the day. What can you do differently to engage more senses?
Kate Zabriskie is the president of Business Training Works, Inc., a Maryland-based talent development firm. She and her team provide onsite, virtual, and online soft-skills training courses and workshops to clients in the United States and internationally. more information, visit www.businesstrainingworks.com.
For
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Four strategies and none hard: make training relevant, connect to why, repeat information using different channels, and incorporate the tools learners should use to solve problems back on the job. If done deliberately and with routine, you will almost certainly get a good result.
People who have mastered the training function know to develop and teach reference tools in addition to processes themselves. Ask yourself what kinds of support you need to develop. Decide where you need to incorporate them in your training plans. Those who learn how to solve problems themselves are worth their weight in gold. In addition to strong productivity, these people are also usually happier and more motivated than those who don’t have the tools to stand on their own feet.
Strategy Four: Teach with Reference Tools
Hi Pro, Inc., a nationwide mail logistics contractor with a 40-year history of servicing the United States Postal Service, celebrated the launch of its propane autogas vehicle fleet at a ribbon-cutting ceremony in Commerce City, Colorado. During the ceremony, Hi Pro, Inc. CEO Joshua Stoneback unveiled the five, class 6 ultra-low nitrogen oxide (NOx) box trucks and state-of-the-art propane autogas infrastructure that will reduce emissions in the Denver metro. www.hiproinc.com Industry
18 September 2022 Material Handling Network www.MHNetwork.com
ARA forecast remains bullish on equipment rental revenue growth despite headwinds Today’s economic indicators are mixed and uncertain, but all continue to point toward significant growth for equipment rental revenue in the U.S. according to the latest quarterly update of the fiveyear forecast released by the American Rental Association (ARA). The update, released Aug. 3, projects equipment rental revenue, including the construction and general tool segments, to grow 11.2 percent to nearly reach $55.9 billion in 2022. ARA expects growth of 6.2 percent in 2023, 2.5 percent in 2024, 3.3 percent in 2025, and 3.7 percent in 2026 to total more than $65.1 billion.
www.womenintrucking.org
Women In Trucking Association announces truck giveaway
News
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Felling Trailers, Inc. has recently received certification for its UN31 Tank design. The UN31 tank is certified as a fuel tank, 607 usable gallons, intended use is for the mobile generator industry. The UN31 tanks were designed to be compatible with Felling’s DDG drop deck generator trailer line. The tank option is utilized in conjunction with an OEM’s Genset mounted to the trailer frame. The tank is certified to meet the safety standards of CAN/CGSB-43.146 for metal IBCs (intermediate bulk containers) for use with liquids in packing group III, such as diesel fuel.
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Industry NewsFor more
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Felling Trailers adds UN31 Tanks to its certifications
The Women In Trucking Association (WIT) has announced its second truck giveaway in partnership with Arrow Truck Sales. The truck is being donated by Arrow Truck Sales of Kansas City, Mo. On March 24, 2023, five years after the first truck giveaway. The giveaway will take place at the annual “Salute to Women Behind the Wheel” event at the Mid-America Trucking Show at the Kentucky Exposition Center in Louisville, Ky.
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Denver USPS Contractor adds Autogas vehicles to fleet
CLARK Material Handling Company exits ITA Industry sources are reporting that CLARK Material Handling Company has apparently departed from the Industrial Truck Association (ITA) which represents the North American Industry and its supply base. CLARK Material Handling Company is headquartered in Lexington, KY. The Industrial Truck Association is an organization of industrial truck manufacturers and suppliers of component parts and accessories that conduct business in the United States, Canada, and Mexico.
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Automation Industry veteran Scott Kilpatrick joins AMT as Vice President of Sales Applied
Mike Zinda named VP of Sales at ePicker ePicker, an elite material handling equipment provider and one of the industry’s fastest growing OEM, has appointed a strategic new addition to its management team to support its goal of becoming the #1 manufacturer of Lithium forklifts in North America by 2025. Mike Zinda, an industry veteran in material handling with over 27 years of experience has been named as the Vice President of Sales to accelerate the growth and expansion of global sales. www.epicker.com
CLARK Material Handling Company appoints Joe Raines as Chief Operating Officer
20 September 2022 Material Handling Network www.MHNetwork.com People News
The American Rental Association (ARA) announces Erika Singleton as the association’s new Workforce Development Manager. With a background in human resources management, employee training, and program marketing, her role will work to address the industry labor shortage by promoting rental as a career. The current ARA workplace initiatives include an industry job portal, best practices documents, customizable job description templates, employee recruitment videos, and an employee recruitment website — exclusively available for ARA member access. www.ARArental.org
AutoScheduler.AI names Keith Moore as CEO AutoScheduler.AI, an innovative Warehouse Management System (WMS) accelerator, names Keith Moore as CEO with Tom Moore, Founder, moving to the Board of Directors. Keith Moore was previously the Chief Product Officer at AutoScheduler. As CEO, he takes on additional responsibilities and will manage AutoScheduler’s overall operations, including driving profitability, managing organizational structure, strategy, and communicating with the board.AutoScheduler has also added Lori Stoia, a seasoned marketing professional, as the new Director of Marketing to evangelize their rapidly-growing market presence.
CLARK Material Handling Company has announced the appointment of Mr. Joe Raines as Chief Operating Officer. In this role, Raines will oversee daily operations at CLARK, working closely with our CLARK dealer network, facilitating the continued innovation of the company, as well as working closely with the CLARK management team to build on the success of the company with a long-term strategic plan. He will report to Dennis Lawrence, President, and Chief Executive Officer of CLARK Material Handling Company. www.clarkmhc.com
of Scott Kilpatrick as vice president of sales. Working together with Chief Operating Officer Craig Salvalaggio, Kilpatrick will focus on growing and leading the AMT sales team, developing engineers and sales personnel to lead fulfilling professional lives in an environment of advancing high performers. www.appliedmfg.com
ARA adds to leadership team focused on Rental Workforce Development initiatives
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announcedTechnologiesManufacturing(AMT)hasthestrategichire
KANSAS: Pet food mfr. is planning to invest $115 million for an expansion of their warehouse and processing facility in EMPORIA, KS. They are currently seeking approval for the project. The project includes the renovation and equipment upgrades on a recently leased 750,000 sf distribution center in EDGERTON, KS.
INDIANA: Specialty food products mfr. is planning to invest $58 million for the expansion of their processing and cold storage facility in LEBANON, IN by 340,000 sf. They are currently seeking approval for the project. Completion is slated for late 2023.
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MICHIGAN: Specialty food products mfr. is planning to invest $55 million for the construction of a 145,000 sf warehouse and processing facility in HOLLAND, MI. They are currently seeking approval for the project. Construction is expected to start in late 2022.
TEXAS: Steel pipe mfr. is planning to invest $38 million for the construction of a 253,000 sf warehouse and manufacturing facility in SPLENDORA, TX. They are currently seeking approval for the project.
SOUTH CAROLINA: Outdoor power equipment mfr. is planning to invest $75 million for an expansion, renovation, and equipment upgrades on their warehouse and manufacturing facility in ANDERSON, SC. They are currently seeking approval for the project.
OREGON: Discount retail chain is planning to invest $168 million for the construction of a 1-million sf warehouse and distribution center in SALEM, OR. Construction is expected to start in Fall 2022.
MISSISSIPPI: Steel tube mfr. is planning to invest $110 million for the construction of a manufacturing, warehouse, and office facility at 1923 Airport Road in COLUMBUS, MS. Construction is expected to start in Fall 2022, with completion for Summer 2023.
FLORIDA: Aviation and logistics service provider is planning to invest $34 million for the construction of a 388,000 sf warehouse and distribution center and aircraft maintenance complex at Tallahassee Airport in TALLAHASSEE, FL. They are currently seeking approval for the project.
GEORGIA: Medical device mfr. is planning to invest $62.5 million for the construction of a warehouse, distribution, and manufacturing facility in JOHNS CREEK, GA. They are currently seeking approval for the project.
www.MHNetwork.com Material Handling Network September 2022 21 Distribution and Supply Chain Project Report Data provided by SalesLeads 156 New Plans for Distribution and Supply Chain Project Investment - Top Locations for July 2022 SalesLeads announced today the July 2022 results for the new planned capital project spending report for the Distribution and Supply Chain industry. The Firm tracks North American planned industrial capital project activity; including facility expansions, new plant construction and significant equipment modernization projects. Research confirms 184 new projects in the Distribution and Supply Chain sector. The following are selected highlights on new Distribution Center and Warehouse construction news. Distribution and Supply Chain - By Project Type • Distribution/Fulfillment Centers - 55 New Projects • Industrial Warehouse - 179 New Projects Distribution and Supply Chain - By Project Scope/Activity • New Construction - 92 New Projects • Expansion - 49 New Projects • Renovations/Equipment Upgrades - 50 New Projects • Plant Closings - 7 New Projects Distribution and Supply Chain - By Project Location (Top 5 States) • Texas - 16 • Georgia - 12 • Florida - 11 • Michigan - 9 • New York- 9 Largest Planned Project During the month of July, our research team identified 6 new Distribution and Supply Chain facility construction projects with an estimated value of $100 million or more. The largest project is owned by Dollar General Corporation, who is investing $172 million for the construction of a 1-million sf warehouse and distribution center in AURORA, CO. Construction is expected to start in early Fall 2022, with completion slated for late 2023. Top 10 Tracked Distribution and Supply Chain Project Opportunities
MASSACHUSETTS: Global shipping company is planning to invest $165 million for the construction of a 560,000 sf warehouse and distribution center on Galleria Mall Dr. in TAUNTON, MA. They are currently seeking approval for the project.
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KEEN Utility Pittsburgh Energy With the release of the Pittsburgh Energy, KEEN Utility incorporates the proven workhiker performance of the original Pittsburgh for a more nimble, easier-wearing work experience.
No-drill Vehicle Mounting Plates keeps your truck fresh and hole-free Larson Electronics has introduced a Made in the USA product to keep your truck hole free when installing small equipment on your truck, such as lights, antennas, sensors, and cameras. Unwanted permanent modifications serve as a valid reason for avoiding such installations until now. You don’t have to worry about making permanent holes on your truck when you have a Larson Electronics vehicle mounting plate.
Polymer Solutions International introduces new Hygienic GMA Pallet Bison Gear & Engineering Corp.is celebrating its proven PowerSTAR® high-efficiency right angle PowerSTAR®gearmotor.offersmaximum power density in a compact profile that does not compromise performance. Its sleek design offers easy mounting in several orientations, ground gearing for low noise, and a variety of frame sizes to fit numerous design specifications.
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22 September 2022 Material Handling Network www.MHNetwork.com
Yale Materials Handling Corporation has been named a 2022 Green Supply Chain Partner by Inbound Logistics. The award recognizes the company’s growing lineup of lift trucks powered by factory-integrated lithium-ion battery power and the Yale Power Suite, a comprehensive range of motive power sources available on a broad lineup of lift trucks. The win marks the 11th consecutive year that Yale has been named a Green Supply Chain Partner. www.yale.com
Product Showcase
In addition to its lighter weight, this mediumduty boot offers additional cushioning and flexibility with comfort enhancements including a KEEN.ReGEN midsole that returns 50% more energy than standard EVA foam, a KEEN.DRY waterproof, breathable membrane, and a TPU shank for midfoot support.
Yale wins green award for advancing and expanding lift truck power technologies
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SolarShield™ – New HMI covers from AttaBox® Enclosures provide the ultimate screen protection AttaBox® Enclosures introduces AttaBox SolarShield™ HMI Covers, providing the ultimate HMI screen protection in the harshest of environments.New, patent-pending AttaBox SolarShield HMI Covers offer the most innovative, durable, non-metallic HMI Covers for use with all enclosure material types. They are ideal for protecting HMI Screens from UV and harsh environmental conditions and are the industry’s only non-metallic HMI covers with side shields.
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HyLite LED NexGen Arc-Cob lamps The NexGen LED ArcCob Lamps are heavy-duty, industrial-grade lamps with highly efficient lighting design and offer excellent illumination all around. Saving between 67%-90% they significantly reduce energy consumption and relamping costs. designed for easy installation in new and existing fixtures, the NexGen LED Lamps are suitable for damp locations and for fully enclosed fixtures which make them excellent for use in a variety of applications.
Keep Dumpsters Clean and Deodorized Don’t just mask issues, eliminate them. Hospeco Brands Group, which comprises Acute Care, Adenna®, HOSPECO®, Nilodor®, and other popular brands, offers the most complete weapon in this fight, the Nilodor Waste Container, and Dumpster System, a product mix developed to keep dumpsters and trash cans, trash rooms, loading docks, and other high-odor areas deodorized and clean. Do not mask odors; rather, their products eliminate them.
Product Showcase
HexcelPack has introduced HexaFil™, an innovative, 100% paper-based void fill solution that provides superior block and bracing and additional cushioning in the box vs. traditional paper and plastic-based void fill options. Available with either automatic or manual dispensing units to accommodate various shipping speeds, HexaFil™ delivers ultimate void fill combined with sustainability benefits, including being curbside recyclable and fully biodegradable.
HexcelPack introduces Sustainable, Cushioning Void Filler Solution
www.hexcelpack.com
Hubtex MaxX 2022: Flexible transport in narrow aisles With the MaxX from Hubtex, the operator can steer smoothly in all directions thanks to the joystick, making the warehouse so much easier to maneuver. The patented HX 360-degree steering from Hubtex is certainly the highlight of the electric multidirectional forklift. The MaxX is now available in several variants: with a load capacity of 3,000 kg and a powerful 48-volt drive or with a load capacity of 4,500 kg and a 48 or 80-volt drive.
www.cementexusa.com
www.ageindustries.com
www.MHNetwork.com Material Handling Network September 2022 23
Cementex highlights feature series of Arc Flash PPE Task Wear Cementex, highlights the Cementex Feature Series of Arc Flash Protective Clothing PPE, designed for those seeking the next level of comfort, safety, durability, and protection. With a focus on safety and usability, the Cementex Feature Series is made with USA labor and materials to ensure the highest quality arc flash protection. Clothing options include coats, parkas, bib/pants, coveralls, and leggings, available in sizes S-5X with a standard inseam of 32". Coveralls include elastic backs for ease of movement, and all coats and coveralls have Nomex® knit wrist cuffs The Feature Series clothing is made with Indura® Ultra Soft® FR treated cotton and meets current ASTM F1506 and F1959/1959M-99 standards. FR Velcro® front closures provide a secure closure, easy access, and rapid removal in the event of arc flash exposure.
24 September 2022 Material Handling Network www.MHNetwork.com ERGONOMIC HOLSTERSENGINESToll Free 877-303-LIFT • 440-943-9546 • FAX 440-943-9547 www.all-industrial.com ✓ Remanufactured engines ✓ Engines in-stock for same day shipment ✓ Quality assured workmanship from people who know the business! ASSOCIATIONS Your direct connection to the Material Handling Industry’s hottest trends, newest products, best management training workshops & represents a wealth of resources for all material handling businesses. www.mheda.org — 847.680.3500 DECKING PROVEN SOLUTIONS ONE SOURCE DACS inc. 800-909-4937 dswanson@dacsinc.com Punch Deck ® & Punch Deck Plus® Open Area Rack Deck FlueKeeper ® Keeps Flue Spaces Open Fire and Heat Barriers Racking / SolidMezzanineShelvingDeckingRackDeck BATTERIES FIND IT. SELL IT. ENJOY IT. forklift-international.com Marketplace For more articles, news, products and more www.MHNetwork.comvisit
www.MHNetwork.com Material Handling Network September 2022 25 Interested in this space? Next Deadline: September 15 www.MHNetwork.com TRANSMISSION REBUILD NEED A REBUILDTRANSMISSIONKIT? ◆ OUR KITS ARE DESIGNED FOR TECHS, BY TECHS! ◆ AIT CARRIES KITS FOR MOST TRANSMISSION www.aittransmission.com800.588.7515STYLES. AMERICAN INDUSTRIAL TRANSMISSION, INC. TIRES At Tires International Corp., we offer a variety of solid tires for forklifts, telehandlers, skid steer loaders as well as larger loaders and other construction equipment. If you don’t see the tire you need on our website or need help in making your selection, call us. We’re always ready to help! “We ship our solid tires nationwide!” (800) WWW.TIRESINTERNATIONAL.NET818-1139 FORKLIFTS PA Industrial Equipment, Inc. Delivering Quality Since 1977PA CONTACT: ROY BRAMM www.PAIndustrial.com610/369-9778 215 S. Washington St. Boyertown, PA 19512 USED FORKLIFTS & INDUSTRIALFORKLIFTEQUIPMENTPARTSRENTALS FIND IT. SELL IT. ENJOY IT. forklift-international.com FORKLIFTS Marketplace
26 September 2022 Material Handling Network www.MHNetwork.com The advertisers’ index is an extra service to the advertisers. The publisher does not assume liability for errors. All Industrial Engine Service 3 www.all-industrial.com American Industrial Transmission, Inc. ...... 13, 26 www.aittransmission.com Amigo Mobility International ...................... WS17 www.myamigo.com AutoScheduler WS5 www.autoscheduler.ai Bishamon Industries WS9 www.bishamon.com Bristol Manufacturing ..................................... 19 www.bristolsteel.com Collision Awareness ................................... Insert www.save-ty.com CombiLift USA ...................................... WS20, 21 www.combilift.com Custom Industrial Products, Inc. / CIP WS11 www.customindprod.com DACS, Inc. 17 www.dacsinc.com Dyna Rack ......................................... A4, WS2, 3 www.dyna-rack.com Flight Systems Industrial Products (FSIP) ......... 9 www.fsip.biz FMH Material Handling Solutions A1 www.fmhsolutions.com Hader Industries Inc 11 www.haderind.com Hammerhead Material Handling ................. WS19 www.hammerheadllc.com Indoff ............................................................... 7 www.indoff.com Joseph Industries, Inc. ..................................... 8 www.joseph.com Mac Rak Inc. WS7, 23 www.macrak.com Nucor Warehouse Systems / Hannibal WS12,13 www.hannibalindustries.com Phoenix Lighting ............................................. 14 www.phoenixlighting.com Superior Engineering ..................................... A3 www.superioreng.com Superior Tire & Rubber Corp. 5 www.superiortire.com Thombert, Inc. A2 www.thombert.com Trelleborg Wheel Systems Americas, Inc. ..... WS6 www.trelleborg.com West Point Rack, Inc. ................................. WS24 www.westpointrack.com White Blaze Equipment ................................... 15 www.whiteblazeinc.com Wy'East Products WS14, 15 www.clearcap.com ADVERTISER INDEX • TRANSMISSIONS • REBUILD KITS • DIFFERENTIALS • DRIVE AXLES • STEER AXLES • TORQUE CONVERTERS TRANSMISSIONS WE KNOW American sales@aittransmission.comTransmissionIndustrialInc.800-588-7515www.aittransmission.com
Our LOOK OUT™ product line offers a versatile line of safety sensors that will alert workers and pedestrians if a forklift or other moving object is approaching just around the corner. Our sensors are great for any traffic area and are quickly becoming a standard for warehouse traffic control. Avoid accidents and potential liabilities to your facility. We have LOOK OUT™ products for just about every safety application for your warehouse, yard, or office needs. Additionally, if you need a custom solution, we will work with you to assure that your safety needs are met to complete satisfaction. When the sensors detect motion in blind spots around a corner or a door way, it begins to flash a warning to the pedestrian or operator who is approaching that intersection. Additionally, sensors will signal the lights on either side of the unit to flash as to indicate someone is approaching the same intersection. Thus, everyone approaching that intersection is informed of movement and will know to proceed with caution. The sensors may be adjusted to specific angles and lengths that will meet the needs of your facility. Signals are sent via bright flashing red LED lights on each visible side of the units.
Alert Employees of Dangerous Collisions BEFORE They Occur!
• Avoid Forklift Accidents • Alert Workers & Pedestrians • Warehouse, Yard and Office Applications • Reduce Liabilities • Increase Up Time LetandpedestriansoperatorsknowifsomeoneisjustaroundthecornerwithourNew LOOK-OUT ™
Currently, we have 42 standard package offerings, ranging from one-way to fourway intersections. These units can be mounted to racks, walls, or ceiling hung for the large units. Additionally, our new DUAL USE series consists of units that can be used INDOORS and OUTDOORS. Our units are Essential for Traffic Control Protect your employees, visitors, and guests from dangerous collisions with forklifts or heavy equipment while walking through your facility. Safety and caution should be an automatic response to your implemented systems. We offer both interior and exterior sensors on our systems that can be mounted anywhere. They help control traffic concerns and communicate that someone is approaching from a spot that may not be otherwise visible.
As workers juggle more projects and deadlines with shorter time constraints, safety can become jeopardized. As this happens, so do accidents.
40% of all forklift fatalities are caused by an individual being struck or run over by a forklift. Many of these accidents and fatalities can be avoided by warning pedestrians and forklift operators of approaching danger. Our LOOK OUT™ sensor alert warning system allows for quick and easy recognition of possible hazardous situations. Why take chances of liabilities when you can avoid accidents and protect your most valuable assets: your employees!
LOOK OUT 1 R LOOK OUT 2 R LOOK OUT 3 R LOOK OUT 4 LOOK-OUT™
AVOID DEADLY AND COSTLY FORKLIFT COLLISIONS
Sensor detects up to 35 feet away,24 hours a day Toll FREE: 888-324-1920 www.CollisionAwareness.com Sales@CollisionAwareness.com Shown: Hall Door Monitor Basic Blind spots, corners, and dangerous intersections can cause series accidents. Wouldn’t it be great if someone was always there to alert you of oncoming traffic? Despite Safety Supervisors efforts, they cannot always be there to prevent collisions. Thankfully, our units are there to scan traffic areas and alert 24 hours a day, 7 days a week. • The Look Out units cover 2, 3, and 4-way intersections. • The Hall Door and Overhead Door units cover hallways and overhead doors. • The Basics detect on one side and alert on the other. • The Dual Use series of units can be used for interior/exterior Examplesapplications.ofthese units are shown below. OVERHEAD DOOR 4 OVERHEAD DOOR BASIC— DOUBLE DUAL USE 12 EXT DOD SensorInterior DOOR TRAFFIC Double Alert Sensor SensorExterior DOOR TRAFFIC Exterior Double Box Interior Double Box LOOK OUT 4 200’130’70’ 50’ Standard35’ 10’-15” The ‘FIT’ Height Awareness Sensors The Fit height Awareness Sensors alert truck drivers of overhead obstacles that may be in the line of an elevated mast. When the sensor beams are broken, the ‘FIT’ lights and audible alarm continuously alert the driver of potential danger. • Choose from 70’, 130’, and 200’ options for distance between sensors. • Sensors and selectable audible can be used for interior or exterior applications. • Great for protecting overhead sprinklers, heaters, lights, and storage; ceiling fans; loading dock awnings and industrial canopies; overhead bridge cranes; interior doorways; and parking garages. TRAFFIC TRAFFIC T R A F F C T R A F F I C MADE in the U.S.A.
A3 The Superior Turret Advantage WhytheSuperior Turret ? • Save Money by Increased Storage Capacity • Not Difficult to Use like the Others • Work Both Sides of the Aisle • Versatility - Rack to Truck • Limit the Learning Curve • Simplicity in Design • Low Maintenance • Multiple Options • Electric or LP www.superioreng.com 800-359-3052 AmericanMade
A4 Customized designs are considered! Portable Stacking Racks • For storing or transport, these long-wearing racks save space & time. • Utilize vertical storage space by safely stacking these racks up to 5-high. • Forklift portable for easy handling of loads up to 4000 lbs & more. • Rugged construction features stand up to heavy industrial requirements. • Save time by moving more material with fewer moves. • Store product up and off the floor preventing product damage. • Racks store easily with little storage space required when not in use. • Standard rack designs/sizes can be changed to meet your specific needs. “Ideal for your customer’s material handling needs.” Call for 800-939-3962assistance.www.dyna-rack.comsales@dyna-rack.com Made in the USA
Warehouse Solutions September 2022 Supplement insert for Material Handling Network
WS2 September 2022 Warehouse Solutions www.MHNetwork.com • Store product up and off the floor preventing product damage. • Racks store easily with little storage space required when not in use. • Standard rack designs/sizes can be changed to meet your specific needs. Portable Stacking Racks • For storing or transport, these long-wearing racks save space & time. • Utilize vertical storage space by safely stacking these racks up to 5-high. • Forklift portable for easy handling of loads up to 4000 lbs & more. • Rugged construction features stand up to heavy industrial requirements. • Save time by moving more material with fewer moves. “Ideal for materialcustomer’syourhandlingneeds.” STOCK AVAILABLEPROGRAM Call for 800-939-3962assistance.www.dyna-rack.comsales@dyna-rack.com Made in the USA Customized designs are considered!
www.MHNetwork.com Material Handling Network September 2022 WS3 Contact Dyna Rack for your customer’s storage needs. 800.939.3962 | sales@dyna-rack.com | www.dyna-rack.com THE DEALERS' SOURCE FOR PORTABLE RACKSTM CUSTOMIZED DESIGNS ARE CONSIDERED STOCK AVAILABLE on some sizes & designs Stack racks utilize vertical storage by safely stacking racks up to 5 high. Add casters to your stack rack cart base to increase mobility and versatility. Dyna Pallet stacking frames turn your warehouse pallet into a stackable rack within Infiniteseconds.sizes available with custom made racks. application.engineeredCustomper PORTABLE STACK RACKS STACK RACK CARTS DYNA PALLET STACKING FRAMES CUSTOM RACKS Made in the USA
2:15 PM – 2:30 PM This new schedule keeps inventory and activities steady while creating numerous additional cross docks. The result is that everything arrives on time, in full. Nobody has to double pick, reprioritize, or panic.
2:30 PM – 3:00 PM In fact, the warehouse accelerator has already looked at the next 48 hours and optimized the schedule for you. Your staff is Warehouse Solutions
A Day in the Life of a Warehouse Planner
2:10 PM – 2:30 PM You need to fill orders, but you don’t have the inbound needed to load an outbound shipment for a 3:00 PM pick-up time. You rush to the phone to expedite unloading more inventory with the inbound supervisor. You have a trailer waiting to load that is blocking dock space planned for another shipment.
A Day in the Life of a Warehouse Planner Using a WMS 2:00 PM Your shift starts and you have 31 inbound loads and 35 outbound shipments scheduled in the next ten hours. The unloading team has been unloading boxes and pallets based on time, not need. The faster the team unloads, in their minds, the better. However, inventory for some shipments has just arrived.
Warehouse process automation is booming like never This story compares a day in the life of a warehouse planner using a warehouse management system (WMS) accelerator versus a day without WMS planning optimization. Even if companies don’t like to admit it, there is a significant amount of wasted labor in warehouse operations due to poor coordination. For example, because receiving and shipping are operating on a different cadence, eliminating work by crossdocking inventory from inbounds to outbounds is totally missed. Or, if it happens, it happens by coincidence rather than by design. Also, due to there being many different responsibilities, all with slightly different objectives, existing warehouse management systems (WMS) often struggle to orchestrate ALL activities. In an ideal warehouse, everybody would work perfectly in concert to get inventory shipped on time and in full.
2:30 PM – 2:45 PM Your staff will now have to double pick that order, causing a snowballing effect that results in a few additional late shipments. Those delays, coupled with a surge in demand, delay two more planned outbound loads.
WS4 September 2022 Warehouse Solutions www.MHNetwork.com
To make a complex process even more confusing, the simple rules built into the Warehouse Management System that are used to orchestrate activities often cause problems. Inventory may not be available when a shipment is loaded. There may be too many shipments and not enough docks. Trailers may sit in the dock because there isn’t capacity to unload everything on the schedule. Or, a campus may have all of the right inventory and capacity, but it is in the wrong building, and transfer shipments are required. Traditional WMS implementations don’t have the analytics to orchestrate decisions that need to be juggled considering all constraints. These challenges equate to millions of dollars in lost money every year at most facilities.
2:45 PM – 3:00 PM Now, another scheduled outbound, slated to leave by 3:15 PM, is short by twenty five pallets that are not in the warehouse. Should you take early retirement or what? A Day in the Life of a Warehouse Planning Using a Warehouse Accelerator Like AutoScheduler
2:00 PM – 2:15 PM Your shift starts, and you have 31 inbound loads and 35 outbound shipments scheduled in the next ten hours. The unloading team has been unloading based on arrival time, not on the schedule that the warehouse accelerator solutions chooses. Plus, inventory for some shipments has just arrived at the warehouse.
2:15 PM Now you don’t have the inventory needed to load an outbound shipment scheduled to depart at 3:00 PM. But, don’t panic as the warehouse accelerator dynamically changes inbound trailer management priorities and reprioritizes a trailer in the yard to cross-dock with the 3:00 PM outbound shipment to prevent a shortage of product. The system creates new plans directing the team on what trailer needs to be at a certain door at a specific time.
www.MHNetwork.com Material Handling Network September 2022 WS5 WMS Accelerator Optimizes Warehouse Activities improve OTIF • manage INVENTORY real-time SCHEDULING • optimize LABOR Contact Us for an initial assessment! info@autoscheduler.ai 615-428-2035 autoscheduler.ai
AutoScheduler then algorithmically uses this information to identify inventory, capacity, and shipping constraints that will cause future challenges. These constraints can then be dynamically scheduled to ensure that when an inbound or outbound shipment arrives, the dock staff have the capacity to act on it. Because of this constraint-based orchestration across all schedules, AutoScheduler is able to not only quickly identify future issues, but also highlight the causes of those issues and potential resolution paths. This full scale orchestration also allows AutoScheduler to create opportunities, like shipping straight from the production line or scheduling more cross docks. At a single Procter & Gamble facility, these opportunities amounted to over $4 million in savings over a single year.
Keith Moore is CEO of AutoScheduler.AI, a warehouse optimization solution that improves on-time fulfillment, labor utilization, and costs for CPG companies. Keith is focused on bringing the future of technology into warehousing. He works with top 10 Consumer Goods, Beverage, and Distribution companies to drive efficiency in distribu tion centers. www.autoscheduler.ai. Prior to launching AutoScheduler. AI, Keith was voted by Hart Energy Magazine as an Energy Innova tor of the Year in 2020, was selected as a Pi Kappa Phi 30 under 30 member, and holds multiple patents in the fields of neural architecture search and supply chain planning. Keith has been published by jour nals and groups like SupplyChainBrain, Inbound Logistics, ISSA and OTC for his work in logistics, cyber security, and predictive mainte nance applications.
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Warehouse Solutions continued Our species is special: Trelleborg experts have designed the new XP1000, the high performing tire that provides greater durability, more stability and comfort, while reducing the environmental impact even when handling heavy duty jobs.
AutoScheduler works by sitting on top of existing WMS, ERP, and even YMS systems to understand the delivery expectations for all warehouses over the next 6, 24, and even 72 hours. Because this solution sits on top of the WMS and other systems, the integration is much easier and quicker.
Versatile and
WS6 September 2022 Warehouse Solutions www.MHNetwork.com perfectly level loaded for all operations, all the time, saving on labor. Now you take another sip of coffee and debate if you want to go hunting or fishing this weekend.AutoScheduler is a WMS accelerator created to help orchestrate poorly coordinated facilities. It adds value by improving OTIF, managing inventory, and creating dynamic schedules that are feasible and change as conditions shift.
www.MHNetwork.com Material Handling Network September 2022 WS7
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Remediation and Protection Proposals Proposals include material, labor, estimated freight and estimated project duration.
Nationwide Expert Installation Professionally trained and certified installation teams guarantee the project is done on-time and on-budget with the least amount of interruption. Training Your team will be trained on how to identify and report emergency damaged rack conditions. Documents from baseline analysis will be used to facilitate this training and future reporting. Mac Rak is an associate member of the Rack Manufacturers Institute. (RMI) We are North America’s largest, most respected turn-key supplier of engineered approved pallet rack repair and protection solutions. Headquartered in the Midwest since 2001, our family owned and operated business achieves constant growth from focusing exclusively on one thing: the engineered pallet rack repair and protection business. Our performance commitment is backed by the “best in class” lifetime impact warranty. Since inception, Mac Rak’s products and processes have developed out of supervision and oversite from the country’s top structural pallet rack Professional Engineers; Seizmic Inc. is our engineer of record. All Mac Rak repair kits exceed ANSI/RMI 16.1 engineering requirements, and are guaranteed to result in a repaired frame as strong or stronger than the original. This strong engineering background has provided a baseline for continued innovative product and service offerings. Offerings range from rack engineering services, to damaged rack assessments, to turn key repair projects, to DIY training programs, to planning and documentation services.
Exceptional vision Bin picking robots are required to handle objects that may be tiny, thin, porous or deformable. The objects might be densely packed, or piled on top of each other. For instance, let’s imagine bottles are lying randomly in a bin, and must be picked and placed on a conveyer belt. A robot interacting with a production line will usually be placed in the same position, every time. So, if the chain suddenly accelerates or decelerates or a productlet’s say a bottle - falls over, the robot’s programmed movements will not adapt to this.
for robots have
A robot would need exceptional vision and sensors. First, to negotiate and grab the randomlypositioned bottles and, second, to perform its task without damaging any bottles. Because robots rely on wide baseline cameras, they can miss objectsif, for instance, they are obscured by shadows - or perform mispicks. In short, bin picking involves an array of tasks that are never the same, which many robots are ill-equipped to contend with.
Another issue for industrial robots are shiny, reflective objects - examples include products with shiny metal surfaces, or that are wrapped in plastic. Light reflected by these surfaces can cause point cloud artifacts, or irregularities, which interfere with the 3D vision systems robots rely upon. These systems determine the location where robots need to pick an object from, and communicate how they need to position the picking arm. However, reflection interferes with the necessary data quality and CAD matching processes, which can cause the robot to perform faulty calculated picking positions.Theseissues often arise from inadequate vision systems. Less-expensive 2D and 3D vision cameras are affordable for smaller manufacturers, but
The act of picking-up and randomly sorting objects may come naturally for humans, who can perform the task countless times each day. However, it’s much harder for robots, which rely on 3D vision systems, data and programming rather than innate Productionintelligence.lineapplications
More advanced 3D vision systems are key to wider adoption of robots According to Universal Robots (UR), in 2019, around 38 per cent of the manufacturing labor force still moved parts manually between bins and manufacturing machines, rather than use industrial robots. Why the slow adoption? For designers and engineers of industrial robots, the random nature of automated bin picking presents some of the biggest challenges. Here, Claudia Jarrett, US country manager for industrial automation supplier EU Automation, explains why better 3D vision systems are the answer.
historically been repetitive, from the first industrial robot systems that appeared on General Motors’ US assembly lines in the 1960s, to modern tasks like screwing lids on bottles. In contrast, bin picking invites all kinds of random external factors. Automated bin-picking robots can reduce the time and costs manufacturers normally spend on these applications, while freeing up human workers to focus on more productive and valuable tasks. But, if that’s true, why were around 38 per cent of the manufacturing labor force still moving parts manually in 2019?
Overcoming the challenges of automated bin picking
Feature Story
WS8 September 2020 Warehouse Solutions www.MHNetwork.com
Let’s look at some of the major challenges of automated bin picking, and what manufacturers can do to overcome them.
www.MHNetwork.com Material Handling Network September 2020 WS9
The technology’s patented Artifact Reduction Technology (ART) also uses a Zivid Two 3D camera, specifically designed to handle reflections caused by shiny surfaces. Robots for all UR’s report also observed that most real-world bin picking deployments were found at large, sophisticated manufacturers like automotive original equipment manufacturers (OEMs). Yet, at the same time, most bins and manufacturing machines are found within small-mediumenterprises (SMEs), which have the least capital and expertise required to create a bin picking system. Therefore, SMEs need cost-effective bin picking solutions that can be easily used by non-experts and newly-trained staff.
A popular choice are solutions by Norway’s Zivid, which develops industrial 3D machine vision cameras and vision software. The company’s industrial Zivid 3D cameras, for instance, offer optimized resolution, precision and trueness to reliably capture both the fine details for large parts, as well as the tiny and thin objects. Other solutions are designed to overcome the effects of point cloud artifacts in automated bin picking. The new Zivid SDK 2.0, for instance, features a special artifacts correction filter that the developers describe as “groundbreaking”.
Energid is among the companies helping to democratize automated bin picking. It offers a complete pre-integrated system with all the necessary complexity, including sensor configurations, imaging and path planning. The system is pre-figured within software previously used in mission-critical applications for NASA spacecraft, and in autonomous robots for oil drilling platforms and surgical applications. Users can simply plug-in and use the robot with no setup required. This reduces installation time to mere hours. The installation and training time are minimal, according to Energid. The robot then performs its tasks without the need for user-defined waypoints or tuning.
Feature Story continued For more Features and more visit www.MHNetwork.com
WS10 September 2022 Warehouse Solutions www.MHNetwork.com
Elsewhere, designers and engineers of industrial robots are attempting to apply Deep Learning techniques to automated bin picking applications. Although artificial intelligence (AI) is very effective for image classification, the results have so-far been disappointing, given the random nature of bin picking.Asrobots and smart sensors increasingly prove their worth, the support of an industrial parts supplier can be vital in helping manufacturers choose the right sensor for their packaging application. Parts suppliers, like EU Automation, can source sensors for packagers, ensuring the transition can be achieved without requiring a complete overhaul. Such advancements, along with ground-breaking technologies like sensor networks and the IoT, can help ensure that robots can handle the moving of parts between bins and manufacturing machines, freeing-up humans’ workers to focus on more demanding and valuable tasks.
many of them are not optimized for piece picking applications. Robots might be able to detect objects with such a solution, but they cannot pick them every time due to scaling, rotation or translation errors.Instead, advanced 3D vision systems are needed that can quickly recognize objects of similar shapes, colors and material. After all, fast sorting is one of the major advantages of bin picking robots — in some cases, the process has been known to double time and costs when performed with humans.
EU Automation stocks and sells new, used, refurbished and obsolete industrial automation spares. Its global network of preferred partner warehouses, and wholly owned distribution centers, enables it to offer a unique service within the automation industry, spanning the entire globe. It provides worldwide express delivery on all products meaning it can supply any part, to any destination, at very short notice.
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WS12 September 2022 Warehouse Solutions www.MHNetwork.com Nucor solutionsSystemsWarehouseisyourwarehousepartner. Nucor Warehouse Systems offers true end-to-end solutions from rack manufacturing and integration services to support from other Nucor businesses including insulated panels, overhead doors, metal buildings and mezzanines. Nucor Warehouse Systems is solving the most complex challenges for our customers every day with well over $1B in integration projects built across North America. By connecting our material handling expertise with broader resources, Nucor Warehouse Systems is ready to help you take on tomorrow’s challenges today. “ “
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The concept behind today’s industrial midsize motorized material handling vehicles can be traced to similar vehicles originally designed to provide a dependable mobility solution for disabled individuals. For example, motorized shopping carts are commonly seen every day across the U.S. providing ease of mobility for the disabled in grocery stores, department stores, and a variety of other retail environments. Also, not to be confused with the rising trend in automated guided vehicles (AGVs) and autonomous mobile robots (AMRs), motorized material handling vehicles are still very much human-operated. However, due to their extremely simple design, relatively low-tech operation, durability, and reliability, they’re much less costly and easier to service than their high-tech counterparts.Mid-sizemotorized material handling vehicles also utilize a variety of detachable cart and/or trailer designs to accommodate loads of different weight capacities. Typical loads range from parcels delivered for distribution throughout a manufacturing floor to tools and heavy spare parts for machinery repairs.
What exactly is a mid-size motorized material handling vehicle?
This white paper covers five “must-haves” to carefully consider when evaluating investing in mid-size motorized material handling vehicles. Something always needs to be moved One of the major drawbacks of traditional forklifts is that they’re not always able to maneuver in tight spaces or down extremely narrow aisles. And for expansive operations — involving long distances due to their huge footprints — relying on manual pallet jacks or pushcarts for an entire eight-hour shift will gradually fatigue the fittest of employees over time. And as with any industrial manufacturer or warehouse operation, there’s always something that needs to be moved. From scrap cardboard in shipping and receiving, spare parts to fix a broken piece of machinery, to transporting janitorial supplies that help keep work stations as well as lavatories clean and sanitary, the need to keep things moving is seemingly endless.
Warehouse Logistics
Must-Have #1: High Durability As with any material handling equipment investment, the capability to withstand a high level of wear and tear is very important. Mid-
Many manufacturing operations, warehouses, and distribution centers are finding themselves in the market for such a beneficial solution to their material handling needs.
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When an industrial manufacturer or warehouse operation needs to move large and heavy items, they typically rely on the traditional forklift. For smaller, lighter loads, a pallet jack or even a pushcart might be just the perfect solution. But somewhere in between lurks an often-ignored middle-of-the-road gap that neither forklifts, pushcarts — and dare we say electric golf carts — are the best approach. One proven answer that’s quickly gaining traction in a variety of industrial environments — filling the void between forklifts and manual pushcarts — is mid-size motorized material handling vehicles.
Top five must haves to look for in Mid-Size Motorized material handling vehicles
www.MHNetwork.com Material Handling Network September 2022 WS17 “The Amigo material handling cart is invaluable from a safety and ergonomic standpoint. Pulling and tugging on carts with 1,000 lbs. was an extreme risk from an ergonomic standpoint. The Amigo has eliminated that threat from our facility. I would suggest safety professionals from all industries take a close look at this product.” Ernie Fryer, Safety Manager, Boride Abrasives Learn more about Amigo Mobility’s midsize motorized material handling line at myamigo.com/industrial Dex Pro+ Burden carrier Comfort grip rectangle steering wheel Durable foam filled tires Padded backrest Optional strobe light Customizable, detachable24-volttrailerbattery system ThrottleAdjustablelevers speed Speed / Fault codes Battery gauge Horn button
Must-Have #4: Proper Load Capacity
Virtually no maintenance requirements or no mandatory service plan will quickly translate to less total cost of ownership (TCO).
Must-Have #5: Maneuverability
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Warehouse Logistics continued
size motorized material handling vehicles that have evolved directly from personal mobility cart design — which has stood the test of time for decades in a variety of heavy-use environments like supermarkets and grocery stores — is a major plus.
The power of right-sizing your fleet Today, “forklift-free” is a growing buzzword in manufacturing facilities and warehouses around the U.S. But implementing forklift-free plans can be extremely challenging. There aren’t many existing plants that can halt operations to design a completely new layout that eliminates the use of forklifts.Instead of complicated logistics and a new layout, first, consider looking at gradually implementing small changes. Right-sizing material handling equipment based on the need of the job can be a more manageable plan than going completely forklift-free.Theresult is using a smaller, more agile option, such as mid-size motorized material handling vehicles. They not only increase employee job
In addition, a mid-size motorized material handling vehicle that features a simple design with the fewest number of operating parts means a high degree of dependability and a product that’s easy to service if ever needed.
Must-Have #2: Engineered for Simplicity & Ease of Use
Based on their size and design, a high degree of maneuverability is one of the stand-out strengths of mid-size motorized material handling vehicles. With a tight 52-inch turning radius (and even down to a zero turning radius on certain models), this type of optimal maneuverability is useful for a variety of applications where a limited amount of space is a factor.
Consider too an employee who’s responsible for preventive maintenance, such as for a company’s numerous fire extinguishers in a large facility. The employee could easily make their entire round of inspections without ever needing to step off of the material handling vehicle.
In contrast with traditional forklifts, mid-size motorized material handling vehicles require virtually no user training for safe operation. And unlike forklifts or other battery-powered material handling vehicles that require dedicated charging stations, being able to plug a vehicle into any convenient 110V outlet for overnight charging is a significant convenience. In addition, an ergonomically-designed low-deck standing platform that’s three inches off the floor dramatically reduces the amount of energy required for operators who need to repeatedly step on/step off their material handling vehicle (such as for parcel deliveries) during their shift.
Must-Have #3: Ease of Service / Virtually Maintenance-Free
And just because mid-size motorized material handling vehicles are relatively compact in size, simple in design, and have a limited number of operating parts compared to other types of material handling equipment, don’t let their appearance fool you.Compared to more cheaply designed products on the market that are considered “throw-away” equipment, well-built mid-size motorized material handling vehicles are much more durable and powerful than they might appear on the surface. Robust tubular steel frames and specially-designed tires that can withstand the sharpest of metal shards are just two features to look for in a high-quality product.
A mid-size motorized material handling vehicle is ideal for load capacities of anywhere from 1,000 to 2,500 lbs. (including the operator), especially when you don’t need to handle significantly higher weight capacities of 5,000, 7,500, or even 10,000 lbs. Many companies just don’t have that kind of need.For example, a 1,000 to 2,500 lbs. load capacity is perfect for a facility that needs to empty scrap cardboard from an exceptionally high number of 55-gallon garbage containers per day. Keep in mind though that while grades of 4% to 6% still fall within the guidelines for safe operation, even a 1% grade will start to limit weight and towing capacity.
Amigo is a manufacturer of motorized shopping carts, material han dling carts, burden carriers, tuggers, and personal mobility vehicles.
4. Find out how the vendor’s customers are using their mid-size motorized material handling vehicles. This will provide you with vivid examples of what such equipment can do for your own company and your valued employees.
1. Identify your most pressing material handling needs and applications.
When
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2. Ask your employees for feedback to gauge their interest level.
satisfaction but help employees perform their jobs more efficiently while safely moving materials throughout their facilities. By right-sizing your fleet of material handling equipment, you’ll further improve safety by containing forklifts where they’re most needed (and appropriate) while using mid-size motorized material handling vehicles for other dedicated purposes, such as for intra-facility transport. considering investing in such highly useful and versatile material handling equipment, here are a few closing thoughts and recommendations:
3. Most importantly, once you decide to talk to a mid-sized motorized material handling vehicle vendor, ask for a demo of their various products. Due to their compact size, an entire product lineup will easily fit in a van for an on-site visit vs. a full-size semi-trailer full of large forklifts.
Warehouse Logistics continued Material Handling TM Hammerhead Material Handling designs and installs state-of-the-art storage and material handling solutions nationwide. This includes both static and dynamic racking systems, from popular selective and drive in racks, to pick modules, pallet-flow racks, automated shuttle systems, push back racks and mobile racking systems. WHY HAMMERHEAD • Faster Return on your Investment! • Systems designed for your application. • Large variety of storage and MH solutions. • Better space utilization in your facility. • More organized, clean and orderly. • Quick, accurate order picking. • Safer workspace for employees. • We - Design it, Maintain it, Expand it. OUR SERVICES • Site Survey & Rack System Designs. • Turn-Key Proposals. • Structural Engineering & Permi. • Warehouse Fire & Safety Consulting. • Project & Site Management. • Pallet Rack Installation. • Repair & Maintenance & Inspections. • Sprinklers, Lighting & Alarm Systems. • Removal, Relocation & Trade-In. Talk to a storage expert today! West: (323) 543-5013 Central: (346) 699-RACK(7225) East: (973) 801-0309
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B e f o r e y o u i n v e s t i n u p g r a d i n g t h e i n f r a s t r u c t u r e o f y o u r w a r e h o u s e , f i n d o u t h o w C o m b i l i f t c a n i n c r e a s e y o u r s t o r a g e b y u p t o 5 0 % W i t h o v e r 2 1 y e a r s ’ e x p e r i e n c e i n v o l u m e o p t i m i z a t i o n , o u r t e a m o f w a r e h o u s e p l a n n i n g e x p e r t s k n o w h o w t o m a k e y o u r s p a c e w o r k h a r d e r f o r y o u . C o n t a c t u s t o d a y t o a r r a n g e a s i t e s u r v e y ! O u r w a r e h o u s e d e s i g n c o n s u l t a n c y s e r v i c e i s F R E E a n d w i t h o u t o b l i g a t i o n . up to 50% more storage with Combilift
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Warehouse Safety
• The direction of travel: Find out more about the clever Combilift approach that enables the operator to change the direction of travel by 90 degrees at the flick of a switch.
• Workplace safety meetings- Regular meetings to discuss workplace safety is important and helpful for everyone.However, there are also many items you can utilize in your workplace to safeguard your employees. This would include noise control systems, industrial curtains, vinyl strip doors, welding and safety screens and fire safety equipment.
• A workplace designed for older operators: Ask how the better layout and easier vehicle access can reduce tiredness and injuries as well as make a workplace easier for more senior colleagues.
www.singersafety.com
www.combilift.com/warehouse-planning
• Workplace training- Training your employees on the proper use of equipment will prevent injuries.
There are thousands of different kinds of businesses and manufacturers creating all types of products all across the country. While they all create different products, one thing ties them all together: workplace safety. Safety in the workplace is a top priority for all of these companies. There are myriad ways that employees can be injured (or worse) in the workplace by industrial hazards like heat, dust, flak, sparks, flash, molten metal, and even noise.
Here are some of the most important things you can do:
Safeguarding your workplace
• Maintaining a clean work area- A messy workspace can lead to unintentional accidents and falls. Keeping your workplace clean and organized can help to prevent this.•Encourage breaks- Even though breaks mean less productivity, your employees will be able to focus on their tasks better and work more efficiently
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There are several ways you can utilize products in order to safeguard your workplace and create a safer work environment for your company, your employees, and yourself: Noise Control Systems, Industrial Curtains, Vinyl Strip Doors, Welding & Safety Screens, and Fire Safety Equipment
There are several things you can do to keep your workplace safe and your employees away from danger.
• Signs and labels- Using signs and labels can warn employees of potential hazards.
A complimentary service using CAD design to find and show your facility's capacity and ideal layout, a Combilift warehouse analysis will provide layout proposals, site inspection, and diagrams to evidence where and how improvements can be made.The free review includes racking layout proposals and storage density calculations to create the best possible performance from any warehouse and will show how to achieve results like the below and more in safer, more innovative ways:
• Long loads…everywhere: You’ll discover how Combilift can maneuver even long loads down narrow aisles, through standard doorways, and around obstacles with ease, enabling racking to be placed closer together, reducing the amount of operational space required.
Combilift offering safety review for warehouse planning Any serious warehouse safety review should also consider a warehouse planning analysis for some simple reasons: there are improvements in visibility, materials handling processes and most of all driver fatigue to be found in looking at a warehouse as a ‘big picture’.
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