Logistics & Materials Handling September 2012

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Mercury Awards Finalists Factory Materials Handling Transport & Logistics Safety Equipment Supply Chain Bulk Handling

Toyota is Australia’s first choice for quality, value, productivity and safety * AUSTRALIAN

FORKLIFT

Post Print Approved PP352583/00436

SURVEY

TMH0285 Toyota Survey Logistics Cover_Art.indd 1

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This issue September 2012

Saving manufacturing supply chains 8 steps to achieving supply chain sustainability

36

behindthecover L MH . S E P 1 2 . P G 0 0 1 . p d f

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Mercury Awards Finalists Factory Materials Handling Transport & Logistics Safety Equipment Supply Chain Bulk Handling

contents 06 Bulletin Board Pacific National signs rail linehaul deal Agility supports largest single-resource project 08 Trend & Developments Top 15 APAC supply chains

Toyota is Australia’s first choice for quality, value, productivity and safety *

12 Factory Materials

AUSTRALIAN

FORKLIFT

Handling

Post Print Approved PP352583/00436

SURVEY

TMH0285 Toyota Survey Logistics Cover_Art.indd 1

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In the recent ‘Australian Forklift Survey’ participants were asked which forklift brand they rated first in the areas of productivity, value, quality and safety.* Not surprisingly most chose Toyota as their No.1 choice. Toyota’s commitment to quality, durability and reliability is the key to its success, and a major reason why so many customers continue to buy Toyota forklifts time and time again.

To see the full range of Toyota Material Handling counterbalance forklifts and warehouse equipment available visit www.toyotamaterialhandling.com.au

Forklifts: swapping diesel for battery Product handling: turning problems into profits Stacking table

Warehouse simulator software

Safety barriers No slip angle plates

16 Bulk Handling Coogee Chemicals reaching new heights Manual dump system Cantilever racking

36 Supply Chain New educational supply chain tool Jeanswest consolidates warehouse operations

18 Mercury Awards

40 Transports & Logistics Heavy haulage in the Pilbara New fees, a tight squeeze for import, export Measuring transport and storage damage

finalists

A record number of finalists!

34 Safety Equipment Reducing musculoskeletal injuries

*Australian Forklift Survey conducted

by Salmat Customer Contact Solutions on behalf of Toyota Material Handling Australia in January-June 2012.

mercuryawards We reveal the official finalists of the 7th annual Logistics & Materials Handling Mercury Awards

18

ASSOCIATE PUBLISHER: Martin Sinclair e martin.sinclair@reedbusiness.com.au DEPUTY EDITOR: Annie Dang t 02 9422 2964 e annie.dang@reedbusiness.com.au GRAPHIC DESIGNER: Justine Dunn t 02 9422 8696 e justine.dunn@reedbusiness.com.au KEY ACCOUNT MANAGER: Mark Ryu t 02 9422 2151 e mark.ryu@reedbusiness.com.au QLD ADVERTISING MANAGER: Sharon Amos t 07 3261 8857 m 0417 072 625 f 07 3261 8347 e sharon.amos@reedbusiness.com.au PO Box 3136, Bracken Ridge, Qld 4017 PRODUCTION CO-ORDINATOR: Mary Copland t 02 9422 2738 e mary.copland@reedbusiness.com.au All rights reserved. No part of the publication may be reproduced or copied in any form or by any means without the written permission of the publisher. ISSN 1832-5513 Copyright Reed Business Information.

Published by Reed Business Information. (ABN 80 132 719 861) Tower 2, 475 Victoria Avenue, Chatswood, NSW 2067 Australia t 02 9422 2999 f 02 9422 2966 Printed five times a year, Logistics & Materials Handling is inserted in the February, April, July, September and November 2012 issues of Manufacturers’ Monthly, FEN, Australian Mining, Electronics News, Food, and PACE magazines with a distribution of 34,000.

4 | Logistics&MaterialsHandling September 2012

Average Net Distribution Period ending March 12 34,806

logisticsmagazine.com.au

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bulletinboard LOGISTICS AND MATERIALS HANDLING NEWS FROM AUSTRALIA AND AROUND THE WORLD

Pacific National signs rail linehaul deal with steel giants

Kuehne + Nagel launches regional aerospace hub KUEHNE + Nagel has introduced

deliveries to operating airport

ASCIANO’S Pacific National

a new regional hub solution in Sin-

terminals handled with the shortest

Rail Business has entered into a

gapore to enhance its dedicated

possible lead times.

new agreement with steel giants,

spare parts logistics offering to the

BlueScope Steel and Arrium (previ-

aerospace industry.

According to Dr. Burkhard Andrich, senior VP aircraft compo-

ously OneSteel), for the continued

Launched in July, the new

nent services, Lufthansa Technik,

provision of rail linehaul services to

hub is a part of the company’s

the dedicated aerospace focus at

both steel giants.

global spare parts logistics solu-

the new regional warehouse allows

tions, and is designed to enable

for total customised solutions.

The linehaul service will involve the movement of approximately 3

global and regional aerospace

million tonnes per annum of a range

customers to supply their clients,

transit times and effective transport

of steel product, including the previ-

flexibly with parts and subsystems

cost, to have our parts being han-

ously announced Jumbo Coil serv-

according to their individual needs

dled by aerospace professionals,”

ice expected to commence in the

and time frames.

Dr Andrich said.

second quarter of FY13, between

Effective from 1 January 2015, the new agreement will

the major steel manufacturing sites

operate for a minimum of 7 years.

at Port Kembla, Westernnport,

Located within the Free Trade

“This enables us, besides good

“Aerospace parts are usually

Zone of the Airport Logistics Park

small and of low weight but of high

of Singapore (ALPS), the new

product value. Therefore it is risky

Whyalla and Newcastle, and to

1 January 2015, for a minimum

operates Pacific National’s rail

warehouse facility will be dedicated

to have them stored together with

steel distribution terminals in the

period of 7 years.

operations with Patrick ports and

to aerospace customers, with

other goods.”

mainland capital cities.

The existing arrangement will

BlueScope Steel and Arrium are longstanding clients of Asciano,

stevedoring businesses.

Pacific National is Australia’s

expire on 21 December 2014,

Australia’s largest national rail freight

largest private rail freight business

and services under the new

and ports operator.

operating in all states and the

agreement will be effective as of

ASX-listed Asciano owns and

Northern Territory.

Agility to support largest single-resource project

CargoWise to dominate logistic market with TransLogix acquisition CARGOWISE has extended its

ate the creation of new software

of the most comprehensive logis-

reach into the domestic logistics

capabilities, expand into new

tics execution software in the world.

market with the acquisition of

geographies and become far more

transport and logistics software

competitive in its core market.

provider TransLogix.

The deal will bring together Australia’s leading domestic transport and logistics software vendor,

The acquisition is a critical step in CargoWise’s company growth plans.

Marine Loading Facility in Henderson, Perth.

TransLogix’s founder and CEO Anselm Waterfield will be assisting

GLOBAL logistics provider, Agility

in the integration and transition of

has won a $238 million two-year

contract underscores Agility’s

the business.

Australian contract to provide logis-

reputation for efficient, effective

tics support for one of the world’s

and highly dependable per-

largest natural gas projects.

formance on complex logistics

Waterfield said the deal is a

“The renewal of the Gorgon

“The addition of the TransLogix

logical and strategic step for

TransLogix with the world’s fast-

domestic transport software skills

TransLogix, and now as part

The Gorgon natural gas project

est growing and most innovative

to our platform will not only boost

CargoWise, the company will

will have Agility providing logistics,

Agility Australasia CEO. Patrick

international logistics execution

our business, it will give customers

be able to extend and invest

stevedoring, and related services

Stevedoring was appointed by

software company, CargoWise.

all aspects of freight operations

extensively to meet its customers’

in support of the Marine Loading

Agility as the prime subcontractor

door to door, road, rail, air and sea

needs with a new, leading-edge

Facility in Henderson, Perth.

for the stevedoring services.

with comprehensive domestic

and across borders from a single

platform and technology.

transport knowledge to comple-

global vendor,” said Richard White,

ment its existing international

CargoWise CEO.

The deal will provide CargoWise

logistics software expertise.

White said the acquisition will

Agility was granted a two-year

assignments,” said Mick Turnbull,

Operated by Chevron, the

extension of its existing contract

Gorgon project is the largest

a unique mix of deep expertise,

to support supply base opera-

single-resource project in Aus-

and proven capabilities that meet

tions and transportation services,

tralia’s history. It is a joint venture

“We will be able to harness

The combined business will

affirm CargoWise’s position at the

the needs of our customers.

in which the stevedoring services

of the Australian subsidiaries

have the capacity to dramatically

leading edge of logistics technol-

There is an exciting and rewarding

have been added. The extended

of Chevron, ExxonMobil, Shell,

increase the level of research and

ogy, and position the company to

future ahead for all stakeholders,”

contract has commenced and will

Osaka Gas, Tokyo Gas and

development investment, acceler-

become the pre-eminent provider

Waterfield said.

run through to 28 April 2014.

Chubu Electric Power.

6 | Logistics&MaterialsHandling September 2012

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trends&developments

Top 15 supply chains in Asia Pacific, 2012

G

LOBAL research and advisory firm, Gartner, has revealed its annual ranking of the top supply chain organisations headquartered in Asia Pacific at this year’s Supply Chain Executive Conference held in Sydney, in July.

The announcement coincided with the release of the 2012 Gartner Supply Chain Top 25: Asia/ Pacific report complied by Gartner analysts, Vikas Sarangdhar and Debashis Tarafdar.

Companies making up the Top 15 are those in the manufactur-

ing, retail and distribution sectors across various industries. According to analysts, these companies best exemplify supply chain best practices which other companies can learn from.

APAC’s Top15 Samsung again leads the Top 15 supply chains in the Asia Pacific in 2012. This year top ranks are dominated by high tech, consumer electronics, automotive, retail and industrial products companies.

Five of the top 15 supply chain companies from the Asia Pacific

region are headquartered in Japan (Canon, Honda, Komatsu, Seven & I Holdings and Toyota), with four headquartered in Korea (Hyundai, Hyundai Heavy Industries, LG and Samsung), two headquartered in China (Huawei and Lenovo).

The only Australian company to make the list is retail giant Woolworths who came in at number 6.

According to report, the company has shown commitment to improving ROA and inventory management over the past year, recording one of the highest ROAs among the top 15.

“Woolworths continued to invest in its supply chain and new stores during the first half of 2012. A key aspect of the retailer’s supply chain strategy includes rationalising its network by significantly reducing the number of distribution centers. The company has also embarked on a major corporate program to improve business efficiency and reduce operating costs,” analysts said.

Woolworths aims to improve its market share and achieve A$1 billion in online sales by 2014.

Other companies in the top spots

Table 1. 2012 Gartner Supply Chain Top 25: Asia/Pacific 2012 Overall Ranking

Company

Return on Assets (ROA)1

Inventory Turns2

Revenue Growth3

Composite Score4

1

13

Samsung

9.4%

17.1

15.9%

3.67

2

31

Hyundai Motor

8.7%

18.0

12.6%

1.95

3

42

Tata Motors

3.3%

5.9

44.0%

1.75

4

43

Lenovo

1.0%

20.8

16.7%

1.75

5

45

Huawei

9.8%

4.9

16.4%

1.73

6

57

Woolworths

10.5%

10.4

4.7%

1.56

7

69

Toyota Motor

0.6%

11.7

-6.6%

1.41

8

76

Asus

7.5%

5.6

14.6%

1.35

9

81

Hyundai Heavy Industries

7.9%

7.5

8.8%

1.33

10

94

Seven & i Holdings

2.8%

20.0

-5.1%

1.11

11

104

Honda Motor

3.2%

7.2

-5.5%

1.03

12

111

Canon

5.7%

3.8

-1.7%

0.88

13

116

LG

-0.4%

20.8

-1.1%

0.83

14

118

Komatsu

4.8%

3.1

3.6%

0.78

15

121

Flextronics

-8.2%

7.7

5.3%

0.72

2012 Asia/Pacific Ranking

Notes 1. ROA: ((2011 net income / 2011 total assets) * 50%) + ((2010 net income / 2010 total assets) * 30%) + ((2009 net income / 2009 total assets) * 20%) 2. Inventory Turns: 2011 cost of goods sold / 2011 quarterly average inventory 3. Revenue Growth: ((change in revenue 2011-2010) * 50%) + ((change in revenue 2010-2009) * 30%) + ((change in revenue 2009-2008) * 20%) 4. Composite Score: (peer opinion * 25%) + (Gartner opinion * 25%) + (ROA * 25%) + (inventory turns * 15%) + (revenue growth * 10%) 2011 data used where available. Where unavailable, latest available full-year data used.

All raw data normalized to a 10-point scale prior to composite calculation.

Source: Gartner (July 2012)

8 | Logistics&MaterialsHandling September 2012

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trends&developments

include India-based Tata Motors, Singapore-based Flextronics and Taiwan-based ASUSTeK. Out of the top 15, four companies entered the Asia Pacific listing for the first time in 2012.

Surviving economic woes While Japanese companies formed the majority of the top 15, Gartner reports that Japanese companies are still recovering from the natural and economic crises of 2011.

These companies are now regaining their stability.

According to Debashis Tarafdar, Gartner research director, Asia Pacific supply chain leaders have maintained momentum in the difficult economic environment by re-configuring their supply chains while staying focused on a demand-driven strategy.

“Companies leading the top supply chains in Asia Pacific A D demonstrated _ L M H P R I capabilities SEP_ 1 2 . pd have in demand management, opera-

Staying focused on demand-driven strategies has kept supply chains afloat.

tional excellence and innovation,” Tarafdar said.

“They are using best practices including demand sensing and shaping, segmentation and collaboration, to help manage demand fvolatility P a gand e deliver 1 1 2predictable / 0 7 / 1 2 , results. To measure supply chain

performance, they select the right metrics that are aligned to the company’s overall business objectives. They also build resiliency into supply network design, and implement risk management strategies 9 : 5 5trading A M partner networks.” across Analysts noted that several

supply chain leaders from the region did not make it into the Top 15 list this year because they did not receive enough votes.

Notable mentions are Taiwan Semiconductor Manufacturing Company, Wilmar International and Wesfarmers.

The Garter report states that some of these and other companies in Asia Pacific could enter the Global Supply Chain Top 25 in the future. However success will depend on how well and how quickly they adopt and adapt global and local best practices to their context.

Earlier this year, Gartner announced its Global Supply Chain Top 25. The ranking is designed to raise awareness of the supply chain discipline and how it impacts business results. From the overall list of qualifying organisations, Gartner identified the top 15 performers headquartered in Asia Pacific, based on revenue growth,

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10 | Logistics&MaterialsHandling September 2012

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trends&developments

return on assets (ROA), inventory and peer opinion.

Gartner’s Supply Chain Top 25, now published for eight years, uses a methodology that comprises two main components: financial and opinion. Public financial data provides a view into how companies have performed in the past, while the opinion component offers insight into the supply chain leadership of the future.

These two components are combined into a total composite score for each company considered.

The Asia Pacific list of companies is derived from a combination of sources, including the Fortune Global 500 and the Forbes Global 2000, with a revenue cutoff of US$10 billion.

The list is then pared down to the manufacturing, retail and distribution sectors to eliminate certain industries, such as finanA Dservices _ L M Hand A Einsurance, C S E P _ that 1 2 do . pd cial

Gartner managing vice president Debra Hofman stated that regional rankings help to capture issues and fbestPpractices a g e that 1 6are / unique 0 8 / 1to2 ,

not have physical supply chains.

each region.

logisticsmagazine.com.au

Woolworths is the only Australian company to make Gartner’s Top15 APAC supply chain list.

Hofman said there were a number of notable trends in Asia Pacific affecting supply chain 4 leaders : 3 0 that P Mincluded: a focus on growth and low-cost innovation;

growing but unpredictable demand with associated demand management challenges; shifting supply bases that require supply chain redesign; growth in intra region trade that helps to buffer global volatility; and rapid inflation, rising and volatile costs and tightening labour market that combine to pose increased risks.

Gartner research director and co-author of the Top 25: Asia/ Pacific report, Vikas Sarangdhar said that while demand in Asia Pacific is growing, inflation, rising costs and a tightening labour market pose challenges for companies in the region.

“Economic challenges in the rest of the world also amplify the risks, as a further sharp fall in exports to advanced economies and capital outflows would impact Asia both directly and through knockon effects on domestic demand,” Sarangdhar said.

Gartner www.gartner.com

September 2012 Logistics&MaterialsHandling | 11

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Why

ELECTRIC is better for

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factorymaterialshandling

Forklift efficiency: a n Pacific BioLogics swaps diesel power for environmentally

No fuel costs The cost to recharge an electric forklift is minimal compared to the equivalent fuel required to operate an engine-powered truck. Electric users also save time and eliminate the safety risks associated with constantly changing gas bottles.

No dirty exhaust fumes With fume-free operation, electric forklifts contribute to a clean and healthy workplace – they are better for your people and better for the environment!

Quieter operation Engine-powered forklifts can be very noisy, especially in enclosed spaces. Electrics, on the other hand, are quiet operators that let the user focus on driving, optimising productivity and safety, and minimising operator fatigue.

Greater reliability With a lot less moving parts, electric forklifts are intrinsically more reliable than engine-powered units. They are also much more durable with many 30+ year-old Nichiyu forklifts still in operation throughout Australia.

Low maintenance costs Electric forklifts are also much cheaper to maintain than engine-powered trucks, with operating/maintenance costs per hour often less than half that of comparable gas trucks.

P

ACIFIC BioLogics, supplier of mosquitocontrol products, has purchased a new battery electric forklift to improve productivity and reduce emissions at its Queensland branch.

The family-owned company commissioned the 1.8-tonne capacity Toyota 7-FBE18 forklift for its Kippa-Ring warehouses in Brisbane’s north, in February this year.

The forklift was to replace a diesel machine from another manufacturer.

Alex Boyd, Pacific BioLogics warehouse manager, said the change to a battery electric forklift has eliminated fuel spills and fumes, and reduced noise at its two Kippa-Ring warehouses.

“One of the two warehouses on this site has an office inside, and switching to the electric machine means people can work in the office without the noise disturbance that the

friendl

previous forklift created,” he said.

Boyd summed up the functions and features new forklift is a “neat bit of gear”.

The forklift will be used to lift sandbags into a cradle, and then lifting the combined 1,300kg of the bag and cradle over a hopper.

It will also be used to unload chemicals from trucks, as part of Pacific BioLogics’ expansion into the rural wholesale market.

The company initially enquired about replacing its old diesel forklift with an internal-combustion machine running on LPG, as part of the company’s “green” push.

However on assessment, Toyota Material Handling suggested a battery electric machine would better suit the task at hand, while also meeting the company’s environmental goals.

Toyota Material Handling Brisbane forklift area manager, Adam

Turning product handling pr oble

Product handling is a real challenge for companies. Howev er a goo

Nichiyu Forklifts Australia Pty Ltd 25 Liberty Rd Huntingwood NSW 2148. Tel: +61 (0) 2 9672 7430. Fax: +61 (0) 2 9672 7423.

33 Kilkenny Court Dandenong VIC 3175. Tel: +61 (0) 3 9554 6555. Fax: +61 (0) 3 9794 7307.

Tel: 1300 369 899 Email: sales@nichiyu.com.au Web: www.nichiyu.com.au

12 | Logistics&MaterialsHandling September 2012

THINGS move quickly in today’s world. Whether companies are shipping directly to consumers, who want next day delivery of their purchases, or to business customers, who demand small regular deliveries on shorter lead times; delivering faster while keeping your handling costs down is becoming a real challenge for industry.

The key is choosing the right equipment to help you handle goods more cost effectively.

Regardless of the type of business, companies will be moving products throughout the facility – between processes, from one end to the other, and ready to supply your customers.

This transportation adds cost to

the company’s products, whether they are being moved at a moderate volume over a short distance or moving many units per hour across the entire length of the warehouse.

With tight OH&S requirements and increasing labour costs, manually handling of products can be very expensive.

Motorised trolleys and automated guided vehicles (AGVs) can carry heavier loads much further than people, which can increase efficiency over traditional manual handling.

For larger goods, forklift trucks and pallet movers are excellent universal handling machines that can also load and unload vehicles, and lift pallets up high for storage. logisticsmagazine.com.au

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factorymaterialshandling

y: a neat bit of gear

entally

PM Pa ge

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Why is better for

friendly battery operated forklifts.

70+ years experience Nichiyu is the largest dedicated and most experienced electric forklift manufacturer in Japan, having produced the country’s first electric forklift in 1939.

Superior build-quality With its on-going commitment to excellence in design and manufacturing, Nichiyu has achieved an unrivalled reputation for reliability and durability.

Proven, reliable technology Nichiyu’s on-going technology innovations including Japan’s first AGVs and automated forklifts, enclosed cabins for cold storage and explosion-proof forklifts for hazardous areas have greatly enhanced forklift performance, reliability and safety.

Alex Boyd, Pacific Biologics Brisbane warehouse manager with the company’s new Toyota 7-FBE18 battery electric forklift.

Gates said the Pacific BioLogics team was provided a ‘whole of life ownership’ comparison between LPG and Battery Electric. This included tables to help calculate the total cost of a unit, including fuel versus battery usage/consump-

tion, operating costs, and recommendations for the battery and charger. Based on the information supplied, Pacific BioLogics chose the battery electric forklift.

Pacific BioLogics 07 3283 5077, www.pacificbiologics.com.au

g pr oblems into profits

High levels of safety From ergonomically-designed operator cabins to impact absorbing masts, travel speed-sensitive lift control, auto-lifting stop and laser pointers for accurate pallet handling and a host of other features, Nichiyu delivers the ultimate in safety in even the toughest of applications.

Factory flameproofing Nichiyu is the only electric forklift supplier in Australia that can offer factory-fitted flameproofing for all hazardous goods handling classes and zones.

Howev er a good conveyor system can turn the tide on poor profits.

However the biggest savings and efficiency gains are made using conveyors. Conveyors are great for straight-forward transportation over short, medium or long distances. And unlike people, they don’t run out of energy after carrying just a few cartons.

Transportation conveyors can flow throughout the facility, eliminating rehandling before and after each process, and can even be loaded and unloaded automatically; reducing the amount of manual handling needed and the cost of handling each carton.

According to Colby Conveyors, more flow, more manoeuvrability and more management control are logisticsmagazine.com.au

Flow, manoeuvrability and control, makes for handling success. what companies should be looking for when it comes to choosing a conveyor solution.

Colby Storage Solutions 02 4040 9586, www.colby.com.au

September 2012 Logistics&MaterialsHandling | 13

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factorymaterialshandling

Ventilated stacking table for palletising

Stop contamination at the factory door FMCG Industry Solutions has released Profilgate, a new

BEUMER Group

foreign matter capturing system which actively captures

has developed a

metal, glass, sand, soil and dust fragments from tyres and

ventilated and spe-

boots, every time they travel over the system.

cially coated layer

The system has been designed to stop the transpor-

stacking table to

tation of contaminants into the factory and warehouse

add to its paletpac.

space by forklift tyres, trolleys and boots, such as dirt and

The stacking table is

potential pathogens.

designed to palletise

Areas protected include entrances into and out of ware-

bags in a careful

The stacking table is pol-

houses, production areas, processing area, maintenance

A wet version is available to not only clean tyres

and dimensionally

ished smooth. Compressed

department and other high risk areas reducing the risk of

and shoes, but to sanitise them as well.

stable manner.

air flows through the small

product contamination and potential recalls.

The table is

Using the latest cleaning technology, the unique brush

holes in the table.

made of smooth

system is activated by the weight of a fork lift as it travels

polished metal, which allows the bags to glide off its surface.

across metal grid and removes contaminants from the tyres

Compressed air flows through small apertures in the layer

and traps them in a stainless steel capture tray.

stacking table to ensure secure handling.

The brushes have specifically been developed with the

This allows the bags to “hover� on an air cushion and

optimal hardness, angle and height to actively capture

collected in the tray to be removed monthly which dramatically reduces on-going cleaning costs.

Unlike most places where cleaners inefficiently move around the site sweeping and vacuuming foreign contaminants using brushes, brooms or floor sweepers after they entered the factory.

greatly reduces the friction between the bag and the layer

metal, glass, sand and soil from staff safety shoes, boots,

stacking table, so that the bags do not stick to the contact

trolley wheels and even forklift tyres, every minute of the

metal and other foreign objects before they enter the

surface. The bags can therefore be moved and positioned

day. It requires no power and very little maintenance and is

production area.

rapidly and in a dimensionally stable manner, resulting in

certified for up to 10 tonnes.

FMCG Industry Solutions 02 8005 6882,

AD_ L M HPR I OAP R_ 1 1 . p d f geometrically precise stacks.

The Profiligate system operates 24/7 collecting glass,

A L E B_ 1 2 . p d f Pa ge P a g e Once 1 installed, 1 7 / the 0 2system / 1 1only , requires 1D 0 _:foreign 2M 8 Hmatter AR M I F Ewww.fmcgis.com.au

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6 / 0 1 / 1 2 ,

Beumer Group 02 9450 0380, www.beumergroup.com

14 | Logistics&MaterialsHandling September 2012

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factorymaterialshandling

Comfort in medium-duty forklift

Warehouse simulator

ADAPTALIFT Hyster’s H50CT

YALE has developed a warehouse simula-

2.5 tonne medium-duty forklift

tor software program designed to provide

is designed for single shift work,

operators of medium to large warehouses

and suits most industries such

with an accurate and sophisticated consul-

as general warehousing and

tancy solution.

distribution, agricultural, bever-

The warehouse simulator can show how

age distribution and bottling, light

a particular forklift fleet in a particular ware-

manufacturing, and retail.

house scenario will perform, and provides a

A lightweight frame and a fuel

platform for trying out different approaches

efficient Mazda 2.2LP engine

and strategies for a warehouse operation.

helps to reduce fuel consump-

The input interface breaks down the sec-

tion and protected lights and

tions of the largest warehouse into atomic

The software provides visual

an advanced cooling system

parts, including marshalling, parking and

representation in 2D and 3D.

reduces downtime.

staging areas, the exact type of racking,

The forklift has an ergonomic

storage and the fleet to be used.

The forklift is designed for single shift work.

design with a high visibility over-

Over 100 different models of Yale forklifts are used so users can see the impact of different

head guard, full suspension seat, lower step and easy three-point entry.

forklift types and performance issues, such as forklift speed.

For improved operator comfort and productivity, the full suspension seat is adjustable. It

Racking and storage variables include; selective, double-deep, block-stack, drive-in and

can help reduce vibration and minimise operator fatigue.

staging/marshalling, while goods flow scenarios include in/out-bound flow and frequency,

The forklift mast is made from a single piece rolled steel, heavy-duty cross members and

order-picking and replenishment, and wave and batch picking. Users can experiment with

loader rollers canted at 3 degrees.

different layouts, racking configurations and timings, and overlay with different forklift options

The cooling system features a wide open counter-weight for maximum airflow and heat

like reach trucks. They can see a visual representation of all scenarios in 2D and 3D, as well

A D _ LThe MH H A K Jradiator U L _is1designed 2 . p dforf maximum P a gaireflow1and 3efficiency.

0 / 0 5 / 1 2 , reduction. serpentine

2 analyse : 0 2 data P using M graphical results and charts. as

Hako_Half Page_122x210mm_July 2012 Ad.pdf 1 29/05/2012 10:07:53 AM

Adaptalift Hyster 1300 758 188, www.aalhysterforklifts.com.au

Yale Asia-Pacific 02 9795 3800, www.yale.com.au/WarehouseSimulation

C

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Delivering commercial and industrial cleaning solutions.

CM

Hako has a complete range of industrial sweepers and scrubber-driers for industrial and warehouse environments.

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Email: industrial@hakoaustralia.com.au

Web: www.hakoaustralia.com.au

Sales

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logisticsmagazine.com.au

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Made in Germany, Hako has the right machine to tackle heavily soiled oors and large dusted areas, keeping your site and environment safe and clean. Contact us today for an obligation-free, on-site demonstration.

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Freecall: 1800 257 221

Service September 2012 Logistics&MaterialsHandling | 15

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bulkhandling

Coogee Chemicals’ new high-density stack action

W

ESTERN Australian Coogee Chemicals produces a range of industrial, agricultural and mineral processing chemicals for supply to both the Australian and International markets, and also provides bulk liquid terminal facilities for import, export and storage of chemicals and fuels.

The company recently purchased the next generation Hyster RS45-31CH Reach Stacker to eliminate specific issues it had with handling chemicals in the past that required contract crane hire.

The RS45-31CH Reach Stacker model is designed for high-density container stacking applications, usually up to 5-high and 3-rows AD_ H B A C with S E Pa _ 1 2 . clean-running pdf Pa ge deep.

It L is M available modern

axle and advanced auto-shift transmission.

Coogee’s Mt Isa fleet contains one reach stacker and a 2.5T forklift. The Reach Stacker is predominately used by Coogee Chemicals to pick up and store Iso-Tanker Containers. These containers hold a reagent product which is supplied to Mt Isa Mines to assist in the manufacturing of Xanthates.

The Reach Stacker is reported to have significantly improve productivity and handling times for the Coogee Chemicals’ Mt Isa site.

Fast and safe handling of Iso-Tanker Containers is essential for Coogee Chemicals day-to-day operations. The end result of Coogee Chemicals’ investment is considerable costs savings and improved flexibility.

1A major 3 0 / focal 0 7 point / 1 2 on , Hyster 1 1 : Reach 1 3 Stackers AM

management systems ensure protection against potentially damaging operational procedures, for example, transmission forward to reverse “shifting lock-out” prevents potential tensional stress being applied to the drive train when changing direction.

In addition, the engine protection and monitoring system initially derates the engine power and finally shuts down the engine when a fault is detected. This safety mechanism is of crucial importance to Coogee Chemicals as safety is an integral part of the company’s workplace culture.

Coogee Chemicals commenced operations in 1971 and has since expanded to 11 sites, currently employing over 200 people.

diesel engine, oil-immersed brakes, robust drive-

is the drivetrain. The transmission and engine

Coogee Chemicals www.coogee.com.au

16 | Logistics&MaterialsHandling September 2012

Adaptalift Hyster 1300 880 335, www.aalhysterforklifts.com.au

logisticsmagazine.com.au

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Pa ge

1

3 1 / 0 5 / 1 1 ,

bulkhandling - Fill or - Empty -

Manual dump system

Bulk Bags Dust Free

FLEXICON has introduced a new manual dump system that collects dust gener-

BulkafilTM, for filling Bulk Bags Latest Technology, one operator

ated during manual tipping, compacts empty bags and

Bulkaflo,

for emptying bulk bags

conveys bulk material

Powder handling requires good experience and the right selection of equipment - trust the Professionals.

downstream.

The dust-free system comprises of a receiving hopper, dust collector, bag compactor and flexible screw conveyor.

HOPPER WALL VIBRATION

A bag in-feed chute through the sidewall of the

MATERIAL AERATION

hopper hood allows the operator to pass empty bags

BLOWER OR COMPRESSED AIR

directly into the bag compactor, causing dust generated

Hopper cutaway of fluidizer

from both tipping and compaction to be drawn onto the system’s two cartridge filters.

An automatic reverse-pulse

Flow and Transfer aids

The system’s enclosed flexible screw conveyor is designed to transport material at any angle.

filter cleaning system releases short blasts of compressed air inside the filters at timed intervals causing dust build-up on

SOLIMAR aerators are the ‘quick fix’ solution for powder flow problems.

the outer surfaces to fall into the hopper, conserving usable product.

The compactor employs a large pneumatic air cylinder to compress bags into a removable bin that accommodates 50 to 80 bags.

The Microveyor

shown mounted under a bulkbag discharge station.

- a small economical pneumatic conveyor TM

for powders and granules. Versions to suit all needs, from 100 kg/hr to 10 te/hr.

Rates to 300 te/hr; vacuum systems too.

The main door and a flapper door within the bag in-feed chute, are equipped with safety interlocks that prevent operation of the compactor unless both doors are closed.

The hopper discharges into an enclosed, flexible screw conveyor designed to handle a broad variety of materials including free- and non-free- flowing bulk materials from large pellets to sub-micron powders.

Flexicon 1300 353 942, www.flexicon.com.au

Cantilever racking for bulky material storage

Ease of a single operator, lifting boards

BOWEN Group Australia has introduced the Unicant cantilever racking, suitable for stor-

TAWI VACUUM-ASSISTED LIFTING

ing long, awkward or bulky products.

Many years experience in developing special models to lift a very wide variety of items, eg. multiple drums, kegs, paint tins, boards, plates, pumps etc.to 300 kg.

Our team would be pleased to arrange a free, real-life demonstration of Vaculift or VacuCobra using our trailer.

The racking has no front uprights and allows easy access for long items that cannot be palletised.

At the same time, it provides support along the full length of the product.

The cantilever is available in single and double sided options and can be galvanised for outdoor use if required.

Cantilever arms can supplied with a wide range of accessories such as end stops, spool holders, and steel planking to create shelf levels.

The racking is self supporting and does not require fixing to walls for stability, while the cantilever arms are securely bolted to prevent them being moved under load.

High speed Cobra in action

All structural components of the cantilever racking are made from IPE sections, ranging from IPE180 to IPE300.

The wide range of profile dimensions provides a broad scope of load bearing

Victorian ENGINEERING EXCELLENCE Awards 2009

Single products to Total Turn-key Systems

The Professionals in Powder Handling and Packaging Systems

capabilities: from 355kg to 2,000kg for the cantilever arms; and up to 35,000kg for the

Head Office VIC - Tel: (03) 9457 8280 Fax: (03) 9457 7695

columns.

Bowen Group Australia 1300 054 719, www.bowengroup.com.au

logisticsmagazine.com.au

MHG1112

www.kockumsbulk.com.au

September 2012 Logistics&MaterialsHandling | 17

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mercuryawardsfinalists

2012 Mercury Awards, a night of nights With close to 60 award entries, this year’s 7th annual Mercury Awards will be the biggest one yet.

W

ITH only a few more sleeps till the 2012 Mercury Awards dinner ceremony, the team at Logistics & Materials Handling have been busy putting the final touches to what will be the biggest awards since its inception in 2005.

This year Logistics & Materials Handling have received close to 60 nominations, with a

record 47 finalists. This year’s Mercury Awards dinner ceremony – to held on Thursday 6 September at Doltone House, Darling Island Wharf, Sydney – is expected to draw a record number of guests to join industry in celebrating Australia’s logistics and materials handling industry’s successes.

The following 16 pages showcase this year’s Logistics & Materials Handling Mercury Awards finalists. The short-listed companies in each category have engaged in providing, delivering new technologies and solutions to help Australian manufacturing, mining and engineering companies better manager their business processes.

The categories for the 2012 Logistics & Materials Handling Mercury Awards are: Top Third Party Logistics Provider (3PL) sponsored by CASI; Technology Application sponsored

by Century Yuasa; Young Professional of the Year sponsored by SSI Schaefer; Logistics Leader and Best Green Initiative sponsored by Logistics & Materials Handling; Supply Chain

tor, Logistics Bureau for their time and expertise during the judging process.

Logistics & Materials Handling would also like to thank all the logistics and materials han-

Innovation sponsored by SmartTrans; Warehousing and/or Storage Solutions sponsored by

dling companies who entered our awards. Thank you for your time and effort in producing

Schaefer Store; Materials Handling Solution sponsored by Century Yuasa; and Best of the

such quality nominations.

Best sponsored by Logistics & Materials Handling. Best of the Best award will be chosen amongst the other categories.

Logistics & Materials Handling would like to thank 2012 award sponsors CASI, SSI

Congratulations to this year’s finalists. We wish you all the best of luck ahead of the awards dinner where the 2012 winners will be announced.

For those companies who would like to attend the 7th annual Logistics & Materials Han-

Schaefer, Century Yuasa, Schaefer Store and SmartTrans for what will be another wonderful

dling Mercury Awards, please book your seats to the Mercury Awards dinner by contacting

event; and returning judges, Kim Winter, Global CEO, Logistics Executive; Phil Lumsden,

Laura Kalyk on 02 9422 2625 or email laura.kalyk@reedbusiness.com.au. All finalists will

NSW General Manager, DHL Global Forwarding; and Rob O’Byrne, Group Managing Direc-

automatically receive two tree tickets to the event.

Materials Handling Solution Proudly sponsored by Century Yuasa

Australis Engineering

Australis Engineering

Mini-linear palletiser solution

High-speed linear palletiser; Tru Blu Beverages, Condell Park

An Australis Engineering client sought to

Tru Blu Beverages are a major pro-

replace a manual palletising process from

ducer of bottled and canned soft drinks,

their product infill line with an automated

including the provision of contracted

palletiser. The palletiser was also needed

services for supermarket chain, Aldi.

to increase production rates and reduce

Following an extensive examination of

OH&S issues resulting from manual han-

palletising alternatives, Tru Blu engaged

dling, while ensuring their unique product

Australis Engineering to provide engineer-

type was safely and securely, palletised for

ing design, manufacture and installa-

delivery to their customers.

tion of a special purpose and custom

Australis provided the client with an

designed High-Speed Linear Palletiser

automated, integrated palletising system

(HSLP) for their Condell Park plant, which

comprising of custom designed infeed conveyors and bag-turner, a semi-automatic stretch

comprised of a quad Head High Speed Linear Palletiser for 1.25L PET soft drink Line S3.

wrapper for the finished pallets, and an integrated safety system.

The MLP-12 mini linear palletiser with customised gripper head and pallet patterns is a low cost, small foot print palletiser capable of palletising products up to 18kg in weight.

18 | Logistics&MaterialsHandling September 2012

By utilising a quad head, the Australis HSLP allows for maximum bottle per minute throughput while minimising required machine velocities, giving the added advantage of less stress on fast moving components.

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SEW-Eurodrive

Intellipack

Swire Cold Storage conveyor upgrade

PAPERplus Chevron Working Comfort system

SEW-Eurodrive provided a range of products and services to Swire Cold Storage Cannon Hill

Storepack’s Paperplus Chevron Belt system offers integration into the given logistics pe-

conveyor upgrade. The Cannon Hill operation handles over 30,000 boxes of chilled product

riphery. Key advantages of the working comfort concept are the prospects of more efficient,

every day, and as production levels have continued to rise over the years at the Brisbane

ergonomic and cheaper packaging. The main aim of the working comfort concept is to

site, so has the need to improve reliability of the equipment – an ageing conveyor system – to

maximise packaging processes, with a view to become as efficient and effective as possible

meet an ever increasing volume of product.

by increasing productivity, whilst decreasing costs.

Since putting in the new drives, downtime has decreased considerably and the customer

NuSkin Australia, a customer of Intellipack, incorporated the Chevron Belt System into its

has ordered three more drives from SEW-Eurodrive. The low-cost project has seen big

warehouse. The project was delivered on time and within budget. Feedback from the client

improvement in Cannon Hill’s production efficiency. Swire Cold Storage is Australia’s largest

was that the new integration system has transformed their packing area, allowing dual opera-

cold-chain logistics service provider with a network of 17 facilities nationwide.

tors to pack, which has increased the overall productivity and efficiency of the business.

ReCoila

Pacific Brands

Sydney’s White Bay Port upgrade

New national distribution centre, Melbourne

ReCoila was required to design

Pacific Brands devised a

highly customised components

project to consolidate the

for two sullage machines at

distribution of several of its

Sydney’s White Bay port up-

leading brands under the

grade. The facility was designed

one roof, at its new 42,000

to cater for all vessels ranging

sqm National Distribution

from recreational to large com-

Centre in Melbourne.

mercial, 8-70m.

The company required

The challenge was to act

that the implemented

quickly as possible to limit the

project provides better

result of downtime at the supply

flexibility, and new order

facility. Working in close techni-

fulfilment technologies to

cal association with Bailey’s

improve service delivery and quality for all customers. This included creating sufficient shelf

Marine Fuels Australia, which in-

space in the DC to provide pick face locations for more than 50,000 SKUs and storage

stalled the facility designed, was key to the success of the project. ReCoila says that for those

for over 25,000 pallets, and the installation of one of the largest raised storage areas in

involved in the project, the benefits can be seen in how their involvement helps the end user.

Australia – over 5,400 sqm – utilising otherwise wasted airspace, and space-efficient narrow

The facility provides a range of marine support services for harbour users, including bulk

aisle storage systems. Consolidating distribution within the new distribution centre provided

diesel and unleaded, lubricants, secure storage, lay down facilities, bilge pump out facilities

benefits and savings right across the supply chain, from reductions in transport and handling

and sullage pump-out facilities.

to improvements in productivity and quality.

Nacco Materials Handling Group

Konecranes

Yale Warehouse Simulator

Lifting solution for Austal ship construction project

Yale has developed a ware-

Designer and constructor of

house simulator; an accurate

commercial and defence ves-

software program designed to

sels, Austal has partnered with

provide operators of medium

crane supplier Konecranes

to large warehouses with a

to develop a lifting solution

consultancy solution.

for large ship sections under

The Yale warehouse simulator can show how a particular

construction.

Austal typically uses 16

forklift fleet in a particular ware-

overhead hoists working simul-

house scenario will perform, and

taneously to lift and move each

provides a platform for trying out

assembled ship section before

different approaches and strate-

positioning into the main

gies for a warehouse operation.

structure. Previously, each

Yale’s consultative approach is performed by the company’s

hoist required its own operator, which means 16 operators were needed. Austal approached Konecranes seeking an improved working method.

warehouse equipment specialists in determining the optimum warehouse design and equip-

A solution using multiple remote controls, whereby a single operator can typically control

ment specification. The software showed that approximately 190 pallet movements per hour

16 designated hoists and up to 20 at a time, was created. Austal said the solution works well

could be achieved.

in practice as it’s easy for the operator to use and is safer as well.

logisticsmagazine.com.au

September 2012 Logistics&MaterialsHandling | 19

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mercuryawardsfinalists

Technology Application Proudly sponsored by Century Yuasa

Trimble Navigation Trimble GeoManager – WesTrac Newcastle project WesTrac was looking for a solution that would drive improvements across multiple fronts, and help centralise the company’s job dispatch and management system.

WesTrac began with a pilot in Thornton NSW, which involved 14 vehicles installed with a GeoManager unit.

Trimble GeoManager is a cloud computing platform that provides a range of solutions to enable businesses of all sizes to improve productivity and increase profits while reducing operating costs.

GeoManager offers visibility into day-to-day fleet operations to identify, manage and improve areas, such as driver safety, customer service, back office administration, fuel use and fleet efficiency, through fleet management, driver safety and work management.

Australian Flameproof Services

Brightstar Australia

iForks forklift mobile weighing system

IT integration project

Australian Flameproof Services identified that one of the major problems faced by parcel express compa-

One of Telstra’s largest dealers wanted to transform their warehousing, 3PL

nies was the amount of time required to weigh pallet shipments.

and supply chain functions. The biggest difficulty in executing this IT integra-

Companies shipping palletised goods would declare the weight themselves and random checks showed that this weight wasn’t always correct.

The customer, DHL, wasn’t able to correctly invoice palletised goods due to the weight discrepancy. They were therefore missing out on significant amount of turnover.

The solution was to weigh the pallets on the same forklift trucks that transport the pallets, in combina-

tion project was because the company was heavily focussed on marketing, as opposed to operational matters.

The key objectives of the project were identified as being: to reduce costs; improve productivity and operational processes; and find a solution to a specific challenge. Best practice was not in place in a range of areas however,

tion with wireless data transfer to the computer system. This solution has been implemented at several DHL

these were overcome by having staff work closely together and also with

Express Hubs.

customers, to achieve better outcomes. The overall accomplishments of the project were reductions in shipment turn around, which meant that costs were reduced due to the increased workspace. There was also reduced freight and IT and software licensing costs.

Pacific Hoists QR Code Program The QR Codes for the Pacific Hoists’ products provide the user with a “point of use” solution. By scanning the code on the product, the user is able to access specifications, technical drawings and instruction manuals in a quick and environment friendly manner. This information can be saved on the smartphone or accessed again through re-scanning the code, meaning the information can’t be misplaced or lost.

The first product range to implement the QR Codes were the Hitachi Electric Chain Hoists with two codes on each product. The first one is placed on the hoist body to provide easy and immediate access to the instruction manuals, and the second code is located on the pendant. These codes will direct users to all Hitachi specifications, technical drawings and the manuals.

20 | Logistics&MaterialsHandling September 2012

logisticsmagazine.com.au

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Epicor Software

JDA Australia

Epicor Mobile Field Service solution

Total Landed Cost (TLC) software solution

Epicor Mobile Field Service is an enterprise mobility solution for field service providers incor-

JDA Australia takes

porating comprehensive field service functionality and full data synchronisation in an easy-

into account TLC

to-use, workflow-based mobile application for wireless PDAs. Epicor Mobile Field Service

for each individual

is used in a variety of industries, including manufacturing, transportation and logistics, local

business to gain a

governments, mining and resources, utilities, and oil and gas.

better insight and

Epicor Mobile Field Service is designed to improve efficiency and productivity for supply

an end-to-end

chain and field service operations across a variety of areas including work order processing,

view of exactly how

work order scheduling and allocation, inventory management and asset management.

much transportation will eventually cost

Printatape Printatape online CRM and ordering

them. To ensure lean operating prices and their own transparency and

Using Cloud technology, Printatape has developed an online CRM and ordering system that

quality, air cargo

allows staff to access whilst out on the road. The system is accessed via the website, and

carriers are put on

consists of two interfaces, one which can only be accessed by members of the company

an appropriate software platform to better anticipate demand, plan for greater capacities and

and one for customers. It’s main objective is to enable Printatape staff access to customer

ultimately meet all these growing demands. The costs of warehousing, or of lost sales due to

information on either an iPad, Smartphone technology or a laptop.

slow surface delivery, could cancel out potential savings, and thus make air freight the more

Since implementation in late May, productivity has increased by 5% due to the efficiency in accessing more data on customer jobs as discussions occur out of the office and over a shorter span of time.

cost effective option.

JDA software facilitates this decision making process. Each application optimises decision making and makes operating this aspect of a business far more cost effective and eliminates guesswork.

Maxitec Installation of Night Train – a totally unmanned 24/7 materials handling solution

Konecranes Konecranes SMARTON crane system

Maxitec has designed, supplied and installed the first ever Night Train, a totally lights-out

Konecranes has developed

unmanned 24/7 materials handling system for fabricator Shamic Sheetmetal, which manufac-

a high-performance modular

tures high profile heaters, including the Coonara.

crane system built to max-

Because the Night Train operates with storage racks (90-100 of them) serviced by auto-

imise safety while minimising

mation, it effectively takes up to 100 pallets off the floor and frees up the work space for other

downtime. The system

uses. In particular, it has allowed management to put more machinery on the floor, which has

is designed to safeguard

helped expand the fabricator’s capabilities, up-skilled staff and allowed the potential for the

deliveries to customers dur-

company for take on more employees as demand increases.

ing equipment changeover, while optimising ongoing efficiencies.

The Konecranes SMARTON crane system – the first SMARTON system delivered in Australia – was developed in a partnership between BlueScope Steel and Konecranes. The project has been followed by other companies in Australia due to the known challenges, technology and high quality.

logisticsmagazine.com.au

September 2012 Logistics&MaterialsHandling | 21

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mercuryawardsfinalists

Warehouse and/or Storage Solutions Proudly sponsored by Schaefer Store

SEW-Eurodrive

Global Track Australia

Swire Cold Storage conveyor upgrades

Newgrove Benchtops

The Swire Cold Storage’s Cannon Hill operation handles over 30,000 boxes of chilled prod-

Global Track has improved the function of existing overhead manual cranes to a higher

uct every day, and as production levels have continued to rise over the years at the Brisbane

standard by developing a new system, which is the world’s first pivotal crane up to 15m in

site, so has the need to improve reliability of the equipment due to an ageing conveyor

length – the longest bridge available.

system and an ever-increasing volume of product.

SEW-Eurodrive provided a range of products and services in the conveyer upgrade at the site.

Since putting in the new drives, downtime has decreased considerably and the customer has ordered three more drives from SEW-Eurodrive.

The low cost project has seen big improvement in Cannon Hill’s production efficiency.

Swire Cold Storage is Australia’s largest cold-chain logistics service provider with a network

The system uses straight-forward engineering principles. The ergonomic design features a pivotal bearing and levered swinging U-hanger producing a crane with fluid motion. The unique pivotal system has the load applied between the pivot points allowing a lever reaction, reducing operator effort. Since implementing Global Track’s Pivotal Bridge Crane and Vacuum Lifter, production at Newgrove has increased considerably. Previously it would take two operators to carry out the same task it now takes one.

The accessional damage to bench tops caused by manual handling has decreased, and

of 17 facilities nationwide.

the new system has also helped improve the company’s OH&S record.

Pacific Brands

Intermec

New national distribution centre, Melbourne

ACC automotive warehouse automation

Pacific Brands wanted to consolidate the distribution for several of its leading brands under the one roof. It also wanted to implement flexible, new, order fulfilment technologies to improve service delivery and quality for all customers.

The company developed a 42,000 sqm DC with 3,700 sqm of canopies and over 30,000 sqm of paved areas on an 8ha greenfields site at Truginina in Melbourne’s western suburbs.

The DC offers sufficient shelf space to provide pick face locations for more than 50,000 SKUs and storage for over 25,000 pallets. Construction of the DC saw the installation of one of the largest raised storage areas in Australia – over 5,400 sqm – utilising otherwise wasted airspace, and space-efficient narrow aisle storage systems Benefits and savings has been delivered across the supply chain through improving order fulfilment productivity and accuracy, implementing voice picking and smart zone-skipping conveyors, and integrating warehouse control and order fulfilment software.

Hobson Engineering Cross-docking and distribution warehouse, Larapinta Hobson Engineering has developed purpose-built cross-docking and distribution warehouse complex at Larapinta, which has

Advance Car Carriers (ACC) is a leading independent Australian logistics supplier. The

been specifically designed to meet unique

company provides on-time car carrying services for the Sydney, Brisbane and Melbourne

product storage and handling challenges the

metropolitan areas, along with regular interstate and intrastate deliveries. Being a high volume

Queensland market requires.

automotive logistics supplier, ACC requires a flexible and responsive communication structure

The new distribution centre, an addition to

to ensure delivery accuracy and efficiency.

the company’s existing Australia-wide distri-

Intermec was employed to implement significant technology upgrades to increase the

bution network, provides over 20,000 pallets

efficiency of ACC’s operations, streamlining a number of processes to further improve their

storage capacity and shelving for provision of

commitment to strong customer service. This included upgrades to their docket generation,

smalls. The new DC comprises of more than 21,000 sqm warehouse storage space.

allocation and completion processing, along with the removal of their paper-based systems.

A key element of the supply chain rationalisation involved consolidating and streamlining

The new system allowed for accurate vehicle survey reports to be done at the pick-up or

operations in Brisbane, into a single new distribution and cross-docking facility designed to

drop off of the vehicle, by the driver or the customer. Additionally, the new system allowed for

meet current and projected distribution volumes for the next 20-30 years. This project follows

proof of service documents to be automatically forwarded to customers, showing them when

the construction of new distribution centres in Perth and Sydney, in recent years.

cars were dropped off, by whom and in what condition.

24 | Logistics&MaterialsHandling September 2012

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LMH.SEP12.PG26.pdf

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mercuryawardsfinalists

Supply Chain Innovation Proudly sponsored by SmartTrans

Pacific Brands

AUNEW

Consolidation of distribution network

GMP’s One Stop OEM Service AUNEW Group consists of several different business entities including GMP Pharmaceuticals and GMP Dairy.

GMP Pharmaceuticals was conceived in response to customer requirements, many of whom were of Asian origin and who wanted to market a range of safe, trusted, natural products in their home regions.

GMP developed its One Stop OEM service in response to this demand. This was originally designed to facilitate access to the Japanese markets however, it then expanded to include Korean and Chinese markets.

This model has been so successful that GMP now services over 800 customers including retail giants and well-known brand players.

The success of GMP’s exports has doubled in a year and turnover is up to $100 million, highlighting the success of its One Stop Service For Export.

Pacific Brands was looking to consolidate the distribution for several of its leading brands to one location; its new 42,000 sqm National Distribution Centre in Melbourne.

In addition, the company also wanted to implement new, flexible, order

Transport Works SWARM solution project The scope of the project instigated by Transport Works for lumbing and building supplier was to take ownership of a $4 million transport and freight logistics function, and transform it from an under-performing one-

fulfilment technologies to improve service delivery and quality for all custom-

size-fits-all solution, into a best practice freight logistics offer, underpinning growth in the domestic distribution

ers. A key safety advantage of voice-directed computing for order picking is

of imported product and branch to branch requirements Australia-wide.

that it leaves the user’s hands and eyes free at all times. This makes handling and picking goods of all shapes and sizes faster and safer.

Consolidating distribution within the new DC has deleiver benefits and savings right across the Pacific Brands supply chain, from reductions in

Ongoing efforts continue to refine all elements of the supply chain function, including imported product wharf cartage, branch point-to-point courier services and state-based requirements, as the clients business continues to grow and expand its national branch network.

As a result of the success of this project, Transport Works has since been engaged by the clients’ New

transport and handling to improvements in productivity and quality.

Zealand operation to replicate the Australian solution.

SAP

CHEP

The Living Lab

High Temperature reusable heat pad

Australia’s first Future

CHEP has designed, devel-

Logistics Living Lab,

oped, tested and manufactured

located at NICTA’s

a pool of new high temperature

Australian Technol-

reusable heat pads for Alba.

ogy Park offices in

Completed with the required

Sydney, Australia, is

12-week period, the heat pads

a dedicated exhibi-

allow Alba customers to reheat

tion, event and work

their solidified tallow ready for

space driven by a

decanting.

group of logistics companies, research organisations, universities, and IT providers.

The concept of The Living Lab is to allow industry to work together to

CHEP’s project brief was to manufacture a sufficient volume of heat pads to meet Alba’s

exchange experience, discuss trends, innovate and research to jointly shape

customer demand in a set time

the future of logistics. The Living Lab makes communication and brainstorm-

frame. The heat pads needed to

ing at the beginning of new projects simpler. It particularly improves collabo-

be able to consistently perform

ration on projects which run across multiple sites.

to the customer’s requirements,

Over the past year, more than 850 visitors have toured the Living Lab,

which was heating the tallow in

including the Australian Prime Minister, members of the Australia Federal

a 24- to 36- hour period. The design and manufacturing system that was set-up allowed CHEP to manufac-

Parliament, as well as international delegations from Germany, China, Japan,

ture additional equipment quickly to meet the customer’s increasing growth. The removable heat pad also

and the US.

allows the customer to use the same IBC for both heated and non heated products.

26 | Logistics&MaterialsHandling September 2012

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mercuryawardsfinalists

Young Professional Proudly sponsored by SSI Schaefer

Anthony Gustafson

Nina Trunk

Australis Engineering

SAP

Anthony Gustafson is an engineering manager and company director of Australis Engineering. As an engineering manager at

Nina Trunk leads the SAP Re-

Australis Engineering, Anthony is responsible for a team of 12 mechanical and electrical/ automation engineers. He oversees

search group in Sydney, and is

all project work at Australis to ensure that jobs are delivered on time and on budget. Anthony coordinates all quoting and job

SAP’s manager of the Future Lo-

tendering, and prepares the most complex and high profile quotations for the business. He is also responsible for ensuring

gistics Living Lab, an exhibition

that engineering design is undertaken to meet ISO9001:2008 Quality Assurance and ISO31000:2008 Risk Management ac-

area and collaborative platform

creditation. As a company director, Anthony contributes significantly to the day-to-day and strategic business planning for the

co-founded together with NICTA

company. He also undertakes all IT related functions within the business, including managing and hosting the network, email

and Fraunhofer and dedicated to

and website. Over the 2011/12 period, Anthony performed a total replacement and upgrade to the company’s website. Other

IT innovation in logistics.

value add and innovations Anthony has contributed to at Australis is the development of a world first Vision Counting System

Since September 2009, Nina has been driving the idea

for coin blanks, engineering design of two new, low-cost mini palletisers, the MLP-10 and MLP-12 and the total redesign of

development, conceptualisation, design, and development

the LowPro slat conveying system.

of the Living Lab’s exhibition space and partner network, together with her team and the two co-founding partners.

Under Nina’s management and in collaboration with co-

James Ellis

founder NICTA, the Future Logistics Living Lab was launched in February 2011. In her role as Living Lab manager, her

eStore Logistics

areas of responsibility include project management and

As the general manager of eStore Logistics, James Ellis manages the receiving and dispatch operation team, customer serv-

operations, supervision of technical set-up and demonstra-

ice team, new business rate costing, client on-boarding, business analytics and management reporting. He has played a key

tion landscape, running events and workshops.

role in the efficiency of operations, human resources, customer service and management accounting aspects of the business.

Under Nina’s watch, Australia’s first Living Lab partner

James has delivered critical aspects of key business projects over the last year including: storage installations specific to

network has grown to almost 30 participants from industry,

online and multi-channel requirements; pick-face installations specific to online and multi-channel outbound order profiles;

research, academia and government. Within 1.5 years since

staging area layouts specific to efficiently and accurately servicing online; multi-channel outbound order profiles; and training

its opening, the Living Lab has hosted quarterly workshops

and induction programs for new staff.

with an average of 40-50 attendees, featuring some excellent

Whilst undertaking these responsibilities cycle time has been reduced by 20 days over six months, and he has also developed and refined industry leading costing and customer pricing models.

guest speakers, lively industry discussions, and leading to 4 new collaborative Living Lab projects.

Rhiannon Buckland

Leigh Williams

Bluescope Steel

eStore Logistics

Rhiannon Buckland is a projects and business improvement

Founder and CEO of eStore Logistics, Leigh Williams has

business analyst in the Bluescope Steel Australia and New

managed every area of the business, including operations,

Zealand, Supply Chain and Processing Development group.

human resources, IT, sales and customer service. As the

The team leads and contributes to a number of business

company grew, Leigh identified that he needed to delegate

process improvements throughout the BlueScope Steel

some of these responsibilities to other staff, in order to focus

Australia and New Zealand (BANZ) businesses.

on strategies for the business. Leigh grew the team to over

Rhiannon has project-managed one of the key logistics warehouse operations improvement initiatives called “block

50 staff in only 3.5 years, enabling him to focus on strategic planning and growth.

stack management”. She lead the project which has deliv-

Leigh is responsible for planning and executing eStore Lo-

ered the first project phase on schedule and under budget.

gistics expansion and growth, managing senior staff, signing

The bottom line improvement of the project will reduce the amount of old/obsolete finished

off on rate proposals and RFQs, leading the development of

goods caused directly by inefficient block stack management.

eStore’s industry-first Warehouse Management System (WMS) and managing key relation-

Rhiannon has also been a project member and sub-project manager in Port Kembla Precinct Project team. The project will deliver consolidation of steel warehouse operations within

ships with freight carriers.

Leigh’s work in building eStore Logistics, a 3PL services for online retailers and traditional

Port Kembla Steelworks. Rhiannon has managed Springhill Overflow capacity sub-project

bricks and mortar businesses in Australia, has added value to the logistics industry through

and a team to establish rail services for export containerized product from Port Kembla to

the creation of jobs and the establishment of a profitable 3PL business. This has also created

Port Botany. Both of these projects provide EBIT improvement opportunity for BlueScope

value for eStore Logistics clients who have been able to take advantage of lower cost and

Steel Australia and New Zealand, Supply Chain and Processing.

high quality logistics services, improving their customer-facing offering.

28 | Logistics&MaterialsHandling September 2012

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LMH.SEP12.PG030.pdf

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mercuryawardsfinalists

Top Third Party Logistics Provider (3PL) Proudly sponsored by CASI

Schenker Australia

MJ Logistics

DB Schenker has continued

MJ Logistics is a family owned and operated 3PL service provider based

its strong “green” logistics

out of Queensland. The company offers local transport services through

approach targeting packaging

to out-sourced national warehousing and distribution across Australia. The

waste. The company oper-

company recently scored a gig to be the service provider for a large corpo-

ates over a dozen facilities in

rate client after a food company provided a reference noting the company’s

Australia to manage its supply

100%positive track record.

chain operations. In each of

MJ Logisitcs aims to provide a superior service to clients in both ware-

these locations, a significant

housing and transport that gives them a competitive edge in their industry.

volume of packaging waste

The company also aims to be a one-stop-shop for all customer require-

is generated as products

ments.The company embraces the use of technology to assist clients, and

are moved through interna-

has installed practical measures such as GPS tracked vehicles, wide mobile

tional and domestic transport

phone usage, as well as the use of RF units. Recently, it updated computer

networks, and as they are

software for stock control at its site.

handled through contract warehousing processes.

Together with its customers, Schenker is accountable for minimising the environmental impact of the complex supply chains it is managing.

To counter this wastage, Schenker introduced a recycling solutions that would reduce, and where possible eliminate waste going to landfill in each of its sites.

Rolled out across Australia, the waste recycling program has seen 65% of material being recycled overall, compared with 25% materials being initially recycled.

The company has also implemented a number of connected projects, including co-mingle bins in office

eStore Logistics eStore Logistics provides third party logistics services (3PL) to online and traditional bricks and mortar businesses. From the ground up, eStore Logistics has developed a modulated warehouse management system (WMS), which is highly configurable to cater for the order profiles of online retailers.

Regardless of the client’s business requirements, the WMS is able to rapidly

area, conversion from gas to electric forklift, set-up of solar water heating and many more. These projects

implement a solution that ensures the most efficient service is provided,

were the outcome of a resource efficiency competition.

which therefore delivers value. eStore Logistics’ 3PL solution developed to service the online retail industry is based on a model that incorporates highly

Transport Works

configurable WMS, as well as a set of order processes that provide a cus-

For over 60 years, Transport Works has

achieved through securing lower rates with existing carriers, introducing ad-

been developing smart solutions that work

ditional carriers and enhancing freight optimisation systems.

tomised solution for each client. Adopted by online retailer Kogan.com, the system delivered a $1.6 million reduction in Australia-wide distribution costs,

around the challenges of the industry to help businesses ultimately get more value from their logistics operations. This includes not only simplify processes and improving service

Brightstar Australia

levels, but often reducing costs. With a head

Global services company, Brightstar is

office in Melbourne, and offices in Brisbane

focused on enhancing the performance and

and Auckland, Transport Works is involved

profitability of the key participants in the wire-

across a spectrum of industries.

less device value chain, including manufac-

Recently, Tranport Works took ownership

turers, operators, retailers/etailers, enterprise,

of a transport and freight logistics company

government, VARs and consumers. Better

worth over $4 million, and transformed that company from an under-performing, one-size-fits-all solution into

management of growing complexities within

a best practice freight logistics offer; underpinning growth in the domestic distribution of imported product

the wireless category better enables compa-

and branch to branch requirements Australia-wide. Across the entire transport spend, a 10% decrease was

nies to increase product availability, extend

realised through consolidation of volumes, improved freight density and outbound consolidation of daily

and expand channel reach, and drive supply

movements. A freight transit warranty process was implemented to ensure the impact of any transport loss

chain efficiencies by getting the right products to the right place at the right

or damage to product was minimised at a branch P&L level, and to provide visibility of the vastly reduced

time at a lower cost. An IT integration project which involved the transforma-

frequency and cost impact of these events. There are also ongoing efforts to refine all elements of the supply

tion of one of Telstra’s largest dealer’s warehousing, 3PL and supply chain

chain function including imported product wharf cartage, branch point-to-point courier services, and state

functions, saw Brightstar deliver a project which resulted in reductions in

based requirements, as the clients business continues to grow and expand its national branch network.

costs, and improvement in productivity as well as operational processes.

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mercuryawardsfinalists

Logistics Leader Schenker Australia

Brightstar Australia

DB Schenker stands for the transportation and logistics activities of Deutsche Bahn. The

Global services

logistics division of DB is the world’s second largest transportation and logistics service pro-

company, Brightstar is

vider based on sales and performance. In the 2011 financial year, over 94,000 employees in

focused on enhancing

130 countries generated sales of around EUR$19.8 billion, more than 52% of the DB Group’s

the performance and

sales. DB Schenker says its vision is to continue being an innovative logistics service provider

profitability of the key

through embracing and implementing “green” initiatives, and collaborating with customers to

participants in the wire-

help them reduce their CO2 emissions in transportation and logistics. Locally, the company

less device value chain,

has continued its strong “green” logistics approach targeting packaging waste across a

including manufactur-

dozen of its facilities in Australia to manage its supply chain operations.

ers, operators, retailers/ etailers, enterprise,

Powerhouse Logistics

government, VARs

Powerhouse Logistics is a fully Australian-owned

focussed on two critical

company which is still being run by the original

metric to customers.

founders. With offices all over Australia, the

Firstly, it is instigating

company has been supplying customers with con-

cost saving initiatives

sultancy services for over 26 years. Powerhouse

achieved through

aims to achieve real cost benefits by minimising

establishing base

customs duty and taxes for those in the importing

lines, continued improvement, and process efficiencies through IT integration. Secondly, it is

community including some of the world’s largest

important to have value creation which is achieved through working with customers closely

multinational companies, such as Unilever, Tetra

to understand their growth and then go to market strategies which offers a lean and agile

Pak and Suzuki. In the past four years, the company has successfully arranged the draw-

supply chain enabling them sustainability and growth. These are achieved through regular

backs and refunds of approximately $2.5 million dollars for Unilever Australasia, and saved

governance and closer engagement with the customer. Recently, Brightstar transformed

Tetra Pak $3 million dollars under the Tradex scheme. Powerhouse is made up of a team that

warehousing, 3PL and supply chain functions for one of Telstra’s largest dealers. The com-

is 80% multi-skilled in two or more facets of international logistics. This allows the company to

pany delivered a project which resulted reductions in costs, and improvement in productivity

deal with peak periods without compromising service levels.

as well as operational processes.

and consumers. The company says that it is

Linfox Logistics Linfox Logistics has grown from humble beginnings to become the largest privately owned logistics company in Australia. Founded by Lindsay Fox, the company started out in Melbourne in 1956, with one truck, delivering soft drinks in the summer months, and fuel in winter.Today, the Linfox business operates more than 3.2 million square metres of warehousing and nearly 5,000 vehicles across 10 countries, and has more than 18,500 staff delivering sophisticated supply chain services to a wide range of leading business names.

Linfox was the first company in Australia to use carbon footprint software to examine its supply chain to find ways to reduce carbon emissions. It is reducing energy use by 3% by changing transport routes, sources of freight and modes of transport within its supply chains. To remind the company and its staff of its green goals and initiatives, the company introduced the ‘GreenFox’. The company says the symbol is representative of its commitment to work together to reduce Linfox’s impact on the environment at work and at home.

32 | Logistics&MaterialsHandling September 2012

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mercuryawardsfinalists

Best Green Initiative Linfox Logistics

A.B. Oxford Cold Storage

‘GreenFox’ initiatives and Eco-Drive program

Design and build of new extensions

Linfox Logistics was the first company in Australia to use carbon footprint software to exam-

To minimise power

ine its supply chain to find ways to reduce carbon emissions. It is reducing energy use by 3%

consumption, electric-

by changing transport routes, sources of freight and modes of transport within the supply

ity costs and carbon

chains. Greenhouse emissions are also being reduced through improved business practices,

emissions, A.B. Oxford

environmentally friendly technologies and the behaviour of staff.

Cold Storage found it

Linfox are also working with its customers and with government bodies across the Asia

necessary to maintain

Pacific to reduce carbon emissions. The company has adopted new provisions and applied

the lowest possible

these internationally for best practice to ensure that performance meets maximum rather than

plant discharge pres-

minimum performance requirements.

sure throughout the

Linfox has also developed Eco-Drive, a program that has seen 3,200 drivers across Asia Pacific trained in fuel efficient driving habits and skills.

year. Oxford identified areas where the plant could have more energy efficient processes to reduce consumption in these areas.

FedEx Express FedEx EarthSmart

For maximum efficiency Oxford installed Variable Frequency Drives to the three large refrigeration compressors in a recently competed building, to control the capacity by changing the rotational speed of the machines. Power consumption has since been reduced at the same rate as the cooling capacity. VFDs condenser and evaporator fans were also installed, which

FedEx works to achieve its sustainability goals through EarthSmart – a company initiative

has seen a 33% reduction in fan speeds, resulting in a 57% decrease in power consump-

to minimise environmental impact. EarthSmart is designed to encourage innovation which

tion. Oxford has also evaluated all fans operating across the site to see other areas where

makes the business more sustainable, both economically and environmentally. This includes

fan speed can be reduced. Oxford has installed a range of other initiatives to reduce carbon

investing in alternative energy sources, adding sustainable vehicles and updating planes,

output and costs within the company.

improving traffic routes, and making sure to reuse and recycle.

The Company has set long-term goals to reduce aircraft emissions intensity by 20% by 2020, increase FedEx Express vehicle efficiency by 20%t by 2020, and expand on-site renewable energy generation and procurement of renewable energy credits. FedEx recently announced it has already achieved 80% of its vehicle fuel efficiency goals for 2020. The company has been recognised in the Dow Jones Sustainability Index.

CST Wastewater Solutions New Bluetongue Brewery, NSW CST Wastewater Solutions designed a water recovery plant to target

Schenker Australia Eco Solutions

world’s best-practice water reuse standards in the food and beverage industry. The recovery plant has exceeded its designers’ expectations

In 2011, DB Schenker launched “Eco Solutions”;

in its first year of service at the new

the company’s green services which actively al-

Bluetongue brewery in New South

lows customers to measure, monitor and reduce

Wales. The waste water treatment

their CO2 emissions from their transport activities.

and green energy plant provides valu-

Schenker further builds on its “green” transpar-

able renewable energy for the brew-

ency initiatives, publishing its CO2 footprint of its

ery, reducing its dependence on fossil

global operations in their annual environmental

fuels and ultimately cutting overall

report. The report outlines Schenker’s climate

energy needs by 15%. Engineered by

change strategy, and the clear targets the

CST Wastewater Solutions in partner-

company has set to reduce emissions across all

ship with Global Water Engineering,

modes of transport (rail, road, ocean freight and air freight), as well as reducing the impact,

the plant has achieved all the high

and minimising the footprint of its operations in warehouses and offices.

environmental performance targets

Schenker has a comprehensive driver training program to educate drivers how to drive

set by the plant’s designer, SABMiller.

efficiently. This long term project has resulted in a 7.5% reduction in fuel consumption. Round

The plant is designed to ultimately

trip distribution has also been executed which has resulted in a 60% reduction in lines, and

have an annual capacity of 150 million litres, while targeting a reduction in water usage to

50% lower emissions from road transport. The company has committed to have all of its own

2.21/1 litres of beer produced. This figure is amongst the best in the world, and above the

and subcontracted Drivers in Europe trained in 2011.

global average of 4-5 litres of water to every one litre of beer.

logisticsmagazine.com.au

September 2012 Logistics&MaterialsHandling | 33

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safetyequipment

Victoria fights to reduce musculoskeletal injuries

M

ANUAL handling is the biggest cause of workplace injury in Victoria. Last year, more than 10,000 people were injured as a result of unsafe manual handling.

In June this year, WorkSafe Victoria launched a year-long campaign targeting musculoskeletal injuries to target the $1 billion problem.

“Musculoskeletal injuries are the most common workplace injury, costing nearly $1 billion a year in medical costs, wages and other expenses,” said Victorian Assistant Treasurer, Gordon Rich-Phillips at the time of the launch.

“They affect the body’s muscles, joints, tendons, ligaments and nerves, are easily prevented, often difficult to treat and can be longlasting and a source of great pain.”

Rich-Phillips stated that every day 43 Victorians are seriously hurt with these sorts of injuries, with an average workers’ compensation claim Musculoskeletal injuries, a $1 billion-a-year cost. costing $55,000 medical costs, wages and other expenses. and falls,” Rich-Phillips said. “These injuries He also noted that Victoria had the lowest are largely hidden because they do not make the workplace injury insurance premiums in nightly news, but the impact on workers, their Australia, stating that the State Government had families and their employer’s business can be slashed WorkCover premiums by 3% to 1.298% in enormous and long-lasting. this year’s Budget – a move he is said is saving “Ensuring people are properly trained and employers $57 million a year. supervised, use the right equipment and clean “Dangerous manual handling particularly liftup spills to prevent falls are no-cost or low-cost ing, lowering and moving things account for measures that will reduce workplace accidents.” about 68% of all musculoskeletal injury claims, Employers have a general duty to make the A D _ L MH S I C S E P _ 1 2 . p d f Pa ge 1 8 / 0 8 / 1 2 , 1 : 5 1 PM while about 20% are the result of slips, trips workplace safe, as well as specific duties in rela-

tion to hazards such as manual handling. They must identify any tasks that involve hazardous manual handling. If these tasks pose a risk of musculoskeletal disorder, they must eliminate the risk.

If it’s not reasonably practicable to eliminate the risk, employers must reduce the risk, as far as reasonably practicable by: changing the workplace layout, the workplace environment or the systems of work changing the objects used in the task; or using mechanical aids. If there is still a risk after using these methods, employers should control it by providing information, training or instruction.

Employers must also review (and, where necessary, revise) workers’ risk controls if things change, if there is a report of a MSD in the workplace, or at the request of a health and safety representative.

While employers are required to protect employees from manual handling injuries, employees also have a general duty to take reasonable care for their own health and safety, and that of others who may be affected by their work, and to cooperate with the employer’s efforts to make the workplace safe.

Employees can also help their employer make the workplace safer by notifying them of any hazardous manual handling tasks that they become aware of.

WorkSafe Victoria 1800 136 089, www.worksafe.vic.gov.au

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34 | Logistics&MaterialsHandling September 2012

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24/07/2012 4:05:19 PM

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LMH.SEP12.PG035.pdf

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safetyequipment

Forklift, pedestrian safety barriers

Anti-scratch safety glasses

No slip angle plates

MATERIALS Han-

ALL Purpose

has introduced a new

dling has released

Abrasives is now

range of carborun-

its A-Safe forklift

offering a new

dum-modified angle

and pedestrian

range of ACE

plates designed to

barriers, made

safety glasses

prevent slips.

from polymer-

designed for

The angle plates

based material.

user comfort

are suitable for ap-

and safety.

plications such as

Unlike steel, the polymer barriers

The barriers are made from

BRONSON Safety

The safety eye-

polymer-based material.

the rungs of ladders

will spring back

wear is available

into shape immediately after impact. The barriers consist of

in clear, smoke or

Three lens colours are avail-

a single 40cm rail with an impact height of 30cm. Standard

amber lenses.

able: clear; amber; and smoke.

post centres are 1.6m with an overall height of 40cm.

or where stair nosing

All lenses are

The hand-rail post extends through the traffic barrier post

is not practical.

They are available in a range of sizes

hard coated to make them anti-scratch. This features aims

and profiles for spe-

to a height of 1.1m. This hand-rail post comprises a 9cm-

to provide long service life and quality vision for extended

cific applications.

square post with two rails.

periods of time.

Designed to protect personnel as well as valuable machinery and equipment, the Traffic Plus barriers provide a clear delineation between vehicle zones and personnel areas.

According to the company, barriers made from polymerbased material will supersede conventional steel barriers.

A D _ LHandling M H A D1300 A S467 E P791, _ 1 2 . pdf Materials www.materialshandling.com.au

logisticsmagazine.com.au

The plates are

The safety glasses provide UV protection and conform to Australian Standards AS 1337.1.

UV-stabilised and

The plates are epoxy-coated for use in harsh conditions.

epoxy-coated to

The range of safety eyewear has been designed to

withstand harsh conditions. They have a Floor Slip Rating

provide a close fit to reduce gap sizes around the edges of

of R13 and the product meets the requirements of AS/NZ

the lenses.

4586:2004.

P a g e All1 Purpose 3 / 0Abrasives 8 / 1 2 02 , 4628 9 : 2800, 5 7 www.allpurposeabrasives.com.au

AM

Bronson Safety 1300 359 545, www.bronsonsafety.com.au

September 2012 Logistics&MaterialsHandling | 35

LMH.SEP12.PG036.pdf

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supplychain

Saving manufacturing supply chains A new educational tool is helping industry reorganise supply chains for better efficiency.

I

T’S a tough market for Australian manufacturers. Poor market conditions have lead to a gradual decline of industry with hundreds of manufacturing companies shutting its doors, just this past year. Those who have managed to survive are yet to report that they are in the all clear.

While there is no rule to manufacturing survival, a new education tool developed by the Plastics and Chemicals Industries Association (PACIA), in collaboration with Sustainability Victoria and Australian plastics manufacturer, Qenos, is providing a fresh source of information to help Australian manufacturers improve and transform their supply chain processes, and hopefully provide longevity to a struggling sector.

Released in July this year, the resource known as the “8 Step Guide to Supply Chain Sustainability”, is designed help the industry identify and take advantage of business opportunities through its supply chains, and to better leverage their supply chains for greater efficiency and benefits to the bottom line.

Available in hard-copy and as an interactive online tool, the resource has the potential for application across the wide manufacturing sector.

“The guide encourages innovation and resource efficiency, and positions member companies to meet customers’ evolving demand,” said Margaret Donnan, chief executive, PACIA. “It is a significant and forwardlooking document, because it recognises that the strength of inextricably linked supply chains is crucial to the strength of Australian manufacturing – and all this at a time when manufacturing is

36 | Logistics&MaterialsHandling September 2012

PACIA CEO Margaret Donnan and Victorian Minister for Manufacturing, Richard Dalla-Riva, inspect Qenos polymer.

under severe pressure from the high Australian dollar, high labour costs and increasing energy prices.”

She said it was important that manufacturers looked beyond the often adversarial world of procurement, contracts and margins towards cooperative projects that would create opportunities to share value with supply chain partners in today’s highly competitive and carbon-constrained business environment.

Donnan said the guide also encouraged PACIA members to turn strong relationships in the supply chain into flourishing business partnerships, and realise the potential of greater collaboration.

For example, she said the Melbourne-based polyethylene and polymer manufacturer, Qenos, had collaborated closely with its logistics provider, Toll Holdings, to deliver product more efficiently and safely direct to customer silos.

The companies had also worked together on alternative supply arrangements that had removed millions of kilometres of truck

transport off the road, delivering large fuel savings and greenhouse gas reductions.

According to Donnan, the Qenos and Toll collaboration is a prime example of how the “8 Step Guide to Supply Chain Sustainability” can help improve resource efficiency to reduce environmental impacts and costs, and strengthen relationships between supply chain partners.

Qenos and Toll collaborate Qenos is Australia’s sole manufacturer and leading supplier of world class polyethylene and polymers.

Ethane extracted from Bass Strait gas is piped to the Qenos plant in the Melbourne suburb of Altona via a dedicated pipeline running along the Port Phillip Bay seabed. Qenos uses this ethane as a feedstock, converting it into ethylene and then polyethylene, which is then loaded into containers and transported to its logistics provider, Toll Holdings, in Laverton.

Santos required long-life piping to gather water and convey gas from coal seam gasfields in South

East Queensland to compressor stations. The gas is then piped to the port of Gladstone for loading onto container ships.

When Santos awarded Iplex the contract to manufacture piping for the coal seam gas project, Iplex called on Qenos to supply its Centrene PE100 polyethylene to keep up with the high volume, continuous manufacturing process.

A key challenge of the project was to increase deliveries from an average of two containers a day to seven or eight containers a day, at relatively short notice. Deliveries were being made from the Qenos manufacturing plant to Iplex’s Thurgoona plant near Albury by road – but this method was no longer feasible, practical or costeffective at the higher volumes.

Qenos and Toll worked collaboratively to develop a strategy to deliver up to eight or nine containers a day, between Melbourne and Albury. The new method involved moving containers by rail between Melbourne and Albury, and delivering from the Albury rail siding directly into the Iplex site.

This approach took more than one million kilometres of truck transport off the roads and onto the rail network, saving fuel and reducing greenhouse gas emissions.

The manufactured pipes are transported and used in the coal seam gasfields in South East Queensland, so the production cycle has gone full circle – Australian gas is supplied, value is added to it, the value-added product is made into piping, which reticulates more gas for Australian and overseas consumers.

PACIA www.pacia.org.au Qenos 03 9258 7333, www.qenos.com Toll Holdings 03 9694 2888, www.tollgroup.com

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MS2689_rsurvey_LMH.pdf

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LMH.SEP12.PG038.pdf

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supplychain

Factory to store: Jeanswest optimises supply chain operations When leading denim brand Jeanswest opened its new centralised DC in Melbourne, the company turned to Manhattan Associates to help it consolidate its warehouse operations.

A

S fashion trends change and evolve so does the need for apparel businesses to update its software and systems.

Recently, leading Australia and New Zealand’s denim fashion brand Jeanswest implemented warehouse management solution – Manhattan SCALE – in a move to optimise its supply chain operations at its new distribution centre (DC) in Melbourne, Australia.

The product suite, supplied by Manhattan Associates, will support the company’s continued growth in local and overseas markets, including China and the Middle East.

Established in 1972, the Perth-born company today operates 3,000 stores across Australia, New Zealand, South East Asia and the Middle East.

Due to the company’s “unprecedented” growth throughout Australia and New Zealand, and more recently in the Middle East and China, Andrew Grant, general manager IT & Logistics at Jeanswest Corporation, said the need to review its entire supply chain operations as crucial in ensuring its global efficiency and growth. “[W]e recognised an inherent need to review our entire supply chain operations and replace our in-house Warehouse Management System (WMS), which was simply too antiquated to support our requirements, both in terms of our physical store locations and our online operations in particular which have expanded exponentially in recent months,” Grant said.

The company’s decision to deploy Manhattan SCALE was driven by a broad review of the company’s supply chain strategy from factory to store. As part of the company’s decision to consolidate its warehouse operations through the opening of a new centralised DC in Melbourne, the company wanted to replace its legacy in-house WMS with a proven, state-ofthe-art solution, based on industry best practice.

Jeanswest wanted a WMS that could facilitate better inventory management and stock accuracy; improve space utilisation within the DC; support new business processes; and provide greater efficiency through streamlined operational processes and greater control of resources.

38 | Logistics&MaterialsHandling September 2012

“The strategy they put in place from the presales stage was extremely structured, and the Manhattan team involved have been nothing but reliable and professional throughout our engagement with them. They have set the bar very high,” he said.

Jeanswest today operates 3,000 stores across Australia, New Zealand, South East Asia and the Middle East.

A new centralised DC and warehouse management solution, sees Jeanswest consolidate its operations.

Following a selection process, the company chose the Manhattan SCALE solution for its flexibility and extensibility in terms of core functionality and features; for its integration strength with third party IT systems including Jeanswest’s enterprise resource planning (ERP) system; and because of what the solution could offer, and support out-of-the-box.

Manhattan Associates was able to demonstrate to Jeanswest the proven success of the suite by facilitating on-site visits with other leading apparel groups based in Australia.

“We have been extremely satisfied with what the solution offers and the type of improvements it can deliver from a supply chain optimisation perspective,” Grant said.

“What we have also been particularly impressed with is Manhattan’s project management approach, both in terms of implementation and execution, which has been simply outstanding.

Jeanwest also expressed interest in the capability of Manhattan SCALE to facilitate data exchange with suppliers from overseas. The company has reported to have seen significant improvements in its receiving and put-away procedures when processing stock sourced from outside Australia.

It has also found the ability to fully integrate with the systems of its domestic freight and online delivery partners a significant value-add from a productivity stand point.

For Manhattan Associates, who provides supply chain solutions to a number of leading retailers in Australia, Jeanswest was an ideal project for the team, according to Raghav Sibal, managing director Australia and New Zealand at Manhattan Associates.

“Our ability to demonstrate a proven track record in the apparel industry specifically was a significant factor in Jeanswest’s ultimate decision to select Manhattan,” Sibal said.

“Manhattan SCALE drives cost savings and increases productivity for its retail sector clients by automating and optimising processes for a more effective distribution network.

“We are delighted that these solutions will serve as the supply chain technology platform that will underpin Jeanswest’s continued growth strategy,” he said.

Jeanswest 1800 888 759, www.jeanswest.com.au Manhattan Associates 1300 787 050, www.manh.com.au

logisticsmagazine.com.au

LMH.SEP12.PG039.pdf

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supplychain

More visibility in Metcash mega DCs Metcash optimises yard and dock operations with Retalix Web Portal solutions.

WHOLESALE distribution and marketing company, Metcash is deploying a number of Web Portal solutions supplied by Retalix in its five mega distribution centres across Australia.

Metcash, which specialises in grocery, fresh produce, hardware, liquor and other fast moving consumer goods, will deploy Retalix’s Yard Management, Dock Scheduling and Transportation Web Portal solutions.

The company will use the Retalix solutions to automate its yard and dock management processes using predictive logic and optimisation algorithms. The software has been designed to assist distributors, like A D _ L in HM M A T J U operational L_ 1 2 . pdf Metcash, eliminating silos, while synchronising yard

logisticsmagazine.com.au

and dock activity with distribution centre demand.

“The solutions will help us efficiently locate equipment, personnel and products anywhere in our yard,” said Phil Mangan, General Manger of IT at Metcash.

“They will also automate scheduling processes, greatly reduce trailer wait times, and ensure Metcash complies with chain of responsibility legislation - all of which means higher supply chain visibility and productivity.”

The Metcash business is spilt into four divisions: Metcash Food & Grocery; Australian Liquor Marketers; Campbells Wholesale; and Mitre 10.

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Metcash will deploy the software across its five mega DCs across Australia.

Metcash 02 9751 8200, www.metcash.com

September 2012 Logistics&MaterialsHandling | 39

LMH.SEP12.PG040.pdf

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transport&logistics

Heavy haulage in the Pilbara As Western Australia’s mines expand, they’re demanding more from haulage companies and local infrastructure, writes Andrew Duffy.

W

ATCHING heavy machinery in action on a mine site can be a rather transfixing experience.

Few industries can match the sheer scale of the mining sector and the size of the equipment it demands. And as production rates grow higher and higher, equipment grows larger and larger.

While many people are impressed by the scale of equipment, few spare a thought for how it made it there in the first place.

Whether its machinery, equipment or buildings, most of the stuff D _ needs L O Gto S slowly I M O Cand T _care0 9 . pdf onAsite fully find its way there.

40 | Logistics&MaterialsHandling September 2012

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A1 Labour Management moving equipment through the Pilbara.

And a lot of this new movement, like everything else in the industry, is starting to centre around the Pilbara region.

Some of the expansions by iron ore companies in this region are immense, and starting to put heavy demands on local infrastructure and businesses to meet their needs.

A number of traffic control companies specialising in moving heavy equipment are now capitalising on this increase.

A1 Labour Management, which specialises in traffic control and moving equipment for mining companies, has been one business to see a sharp rise in demand from Pilbara miners.

logisticsmagazine.com.au

LMH.SEP12.PG041.pdf

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transport&logistics

Wayne O’Neil from A1 Labour Management told Logistics & Materials Handling some of the Pilbara’s biggest players, including BHP Billiton and Fortescue Metals Group, had been driving the rise in mining’s heavy haulage.

Traffic control companies specialising in moving heavy equipment are moving in and capitalising on iron ore expansion in the Pilbara region.

O’Neil said developments further south had also kept A1 busy.

“With all the different expansion projects happening at the moment, from now until the end of the year

we’re going to be very busy with it,” he said.

“There’s definitely a couple of years worth of work happening out here.”

Recently, A1 has been managing the movement of several large loads for FMG. “We did a lot of stuff for them with Cloudbreak and Chirstmas Creek,” O’Neil explained.

“But we’ve worked with a lot of different companies. We’ve done stuff for BHP Billiton as well as Citic Pacific.

“In the past, we’ve moved equipment for the Yandi and Area C mines, and work for Jimblebar is about to start next month.”

O’Neil said demand would also rise as Hancock Prospecting’s massive Roy Hill project, lead by Gina Rinehart, started construction.

With most of this work the starting point for the equipment is Port

Hedland. O’Neil said after being manufactured in China, Thailand, and other parts of Asia and the world, the equipment was shipped to the Pilbara port.

But because of the size, moving it through the Pilbara’s long narrow roads presents some challenges.

O’Neil said sometimes the gear reached dimensions around 15 metres high and 15 metres wide, and prior to the move crews would need to clear the road to make sure the equipment would fit.

And because of the safety liability, the equipment is only moved at night.

“It’s a safety issue, plus the volume of traffic is quite considerable during the day where as night it’s not,” O’Neil explained.

“We mainly go down the highway at night, and it usually takes two nights to complete the delivery,” he added.

Measuring transport, storage damage THE Lamerholm 298 ShockLog range is a complete motion-monitoring instrumentation solution that combines advanced tri-axel piezo electric accelerometer technology with the latest in MEMS electronic accelerometers in a single unit.

Available from Warsash Scientific, the range has been designed to monitor shock and vibrations based on acceleration or velocity measurements. Tilt or roll is measured in degrees of angle (+/- 180 degrees). It can also monitor temperature, humidity and changes in atmospheric pressure.

Tilt and roll sensors extend the monitoring capabilities to include the tilt (front-to-back) and roll (‘Sway’, left-to-right) movement of an object being monitored.

The ShockLog records the data within the timeslot memory as the highest angle of movement both + and – during any given time period as well as being able to identify

Optimal modes of transportation, route, storage options is indentified

full 180 degree turnovers of a product.

through full-journey and motion profiling.

GPS coordinates are recorded within the ShockLog memory. The units will record the

with the GPS coordinates being added to

into specific problem areas to identify

GPS coordinates at the end of each sum-

both the summary and event information.

problematic periods within a journey or

mary interval as well as at the point of every

From within the Windows-based software

storage period.

event. Upon downloading the data, users

programme, users are able to view the angle

Warsash Scientific 02 9319 0122,

can access all of the usual ShockLog data

of motion in the timeslot graphs, zooming

www.warsash.com.au

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September 2012 Logistics&MaterialsHandling | 41

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LMH.SEP12.PG042.pdf

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transport&logistics

A tight squeeze for import, export INTERNATIONAL trade costs in Australia is expected to rise following the decision by major container shipping lines to reduce the free time available for import containers to be de-hired, and for export containers to be returned full for export.

Effective as of 1 August 2012, major shipping lines Maersk Line, ANL, CGM-CMA, and Mediterranean Shipping Company (MSC) have changed their Container Free Time and Container Detention Tariffs charged to importers and exporters.

In most cases, the import container free time period has been reduced from 10 calendar days to 7 calendar days.

According to the Victorian Transport Association (VTA), this means that from the first day of availability and from the day of discharge for some lines, importers will have only 7 days for the container to be collected from the wharf, delivered to the unpack point, unpacked, and then returned for de-hire to a designated empty container park.

AVTA D _ chief L M Hexecutive, D M F A PNeil R _Chambers 1 1 . p ddescribed f Pa ge

blatant exercise in revenue-raising by these market dominant shipping lines.”

“The shipping lines know that many shippers will not achieve these container turnaround times through their inland logistics chains,” Chambers said.

“As a result, the shipping lines are banking on collecting many more thousands of dollars in container detention charges per annum to boost their flagging freight rate revenues.

“Add in weekends, perhaps a public holiday, quarantine inspections and treatments, Customs X-Ray, inland transport, time to pack or unpack the container, then the time needed to return the empty container to a de-hire facility – in many instances it will be impossible to achieve this task in seven calendar days.”

The introduction of these fees is expected to add to the commercial and operational tension between supply chain participants.

In response, the VTA has recommended to 1 transport 1 8 / 0 2operators / 1 1 , that 1 0 they : 4 should 9 AM road

their clients of the availability of empty containers for de-hire. Transport operators should also charge the true costs of additional handling and administration, when they need to stage containers through their transport depots, including times when empties must be staged before they can be transported for de-hire at the required empty container park.

“Importers, exporters and freight forwarders need to factor in these new container detention rules. They should have in place systems to track container “free time“, and should make early contact with shipping lines if it becomes clear that containers will not be able to be returned before container detention fees apply,” Chambers said.

However, the main thing to keep in mind is the potential additional costs of container detention when making a decision to ship with the shipping lines, who have introduced these unrealistic container detention rules, Chambers stated.

these tighter container detention rules as “a

require at least two business days notice from

www.vta.com.au

42 | Logistics&MaterialsHandling September 2012

Victorian Transport Association 03 9646 8590,

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LO2619_LOG_MA_SEP.pdf

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2012 The Mercury Awards recognises individuals and companies that have contributed to the success of Australia’s logistics and materials handling industry.

DATE:

Thursday 6th September 2012

TIME:

6:30pm – pre dinner drinks 7:00pm – Logistics Mercury Awards Presentation

VENUE:

Doltone House, Darling Island Wharf, Sydney

UR O Y Y BU OW N S T TICKE

TICKETS: $150 per person or $1,300 for a table of 10 (exc GST) – Includes three course dinner and beverages To book your seats to the Logistics & Materials Handling Mercury Awards dinner please contact: laura.kalyk@reedbusiness.com.au or phone 02 9422 2625.

For further information please visit www.logisticsmagazine.com.au/awards

AD_LMHHYUAPR_12.pdf

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