modern materials handling - february 2011
TRANSCRIPT
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SYSTEM REPORT
Simon & Schuster set a textbook example 42
SPECIAL REPORT
2011 conveyorsurvey 66EQUIPMENT 101 SERIES
Rack basics 60
®
m m h . c o m
PRODUCTIVITY SOLUTIONS FOR DISTRIBUTION, WAREHOUSING AND MANUFACTURING
February 2011
SPECIAL ISSUE
CHICAGO, 2011
Putting productivityto work
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mmh.com Modern Materials Handling / F e b r u a r y 2 0 1 1 3
Psion has shortened its operating company name, removing the name “teklogix.” Psion’s corporate identity has also been refreshed to work better in the digital world. according to the company, these devel-opments mark the next stage in the company’s transformation and reflect the group’s business strategy.
“our research showed that we had to remove the word ‘teklogix’ from our name, to unite the business around one, clear, global identity,” said John Conoley, Ceo of Psion (www.psion.com). “We found that the complexity of the dual company name was impacting our business by confusing our customers, resellers and other key
stakeholders, especially in new markets for Psion.”
Psion is no. 8 on Modern’s top 20 adC suppliers list, reporting $155.1 million in revenue in 2009.
omron sCientifiC has partnered with the alabama robotics technology Park (rtP, www.alabamartp.org) to complete a three-phase project that will consist of individual training facilities targeted to a specific indus-try need, which will provide college level courses on every aspect of robotics training, including robotics safety. omron is the primary robot-ics safety provider for the project.
“the vision of alabama Governor Bob riley, the rtP is a collabora-tive effort between the state of alabama, Calhoun Community
College, aidt, which is alabama’s workforce training agency, and robotics industry leaders,” said ed Castile,
aidt executive director. “the mission of the rtP is to provide a technically trained, highly skilled, and educated workforce for cur-rent and future automation and robotics technologies, to assist public and private entities in developing new robotics systems and technologies, and to promote the growth and expansion of companies through new robotics technologies.”
redPrairie Has reCentlY added the expertise of three soft-ware companies to its portfolio. redPrairie (www.redprairie.com) has acquired:• Shippers Commonwealth, a pro-vider of software-as-a-service trans-portation management systems and collaborative transportation solutions;• SofTechnics, a provider of inte-grated retail enterprise solutions and inventory management solu-tions that has been serving custom-ers for more than 20 years; and • Escalate Retail, a provider of all-channel commerce to specialty retailers, direct marketers and big-ticket retailers.
Alabama Robotics Technology Park to educate in robotics, automation
23%segment of Modern’s readers surveyed who
say they plan to spend more on conveyors in the next 18 months. see story, page 66.
redPrairie grows by three
PeCo pallets now available in Mexico
FAST FACT
UP FRONT B r e a k i n g n e w s y o u s h o u l d k n o w
Psion drops “Teklogix” from name
PeCo Pallet is noW shipping its signature red wood block pallets to manufacturers and retail-ers in mexico. in december 2010, it registered “PeCo Pallet méxico” as a legal entity and an authorized importer of record.
“We are excited about our recent growth in mexico. this represents the next step in our com-pany’s service expansion,” said david lee, Ceo of PeCo Pallet (www.pecopallet.com).
PeCo has established a manufacturing base in mexico, with a plant in Guadalajara that will manu-
facture, repair and store pallets. Pallets built in mexico can be shipped either to the United states or mexico. to comply with international regulations, PeCo
applies certified heat treatments to all pallets ship-ping into mexico and also to pallets shipping back to the United states.
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mmh.com MODERN MATERIALS HANDLING / F E B R U A R Y 2 0 1 1 5
PRODUCTIVITY SOLUTIONS FOR DISTRIBUTION, WAREHOUSING AND MANUFACTURING
VOL. 66, NO. 2
DEPARTMENTS & COLUMNS 3/ Upfront
7/ This month in Modern
19/ Lift Truck Tips: Attachments
40/ Supplement: Warehouse & DC
77/ Focus On: Lift trucks
82/ 60 Seconds with...
NEWS 9/ ProMat 2011 ready for 30,000 attendees
14/ Behind Intermec’s acquisition of Vocollect
15/ ISM’s January manufacturing data shows strong momentum to begin 2011
COVER STORYPROMAT 2011 SHOW PREVIEW
22 Putting productivity to workProMat 2011, slated for March 21-24, 2011 will showcase more than 700 exhibits and include a comphrehensive educational conference. The event, held at McCormick Place in Chicago, will offer an array of products to help improve productivity at your company.
FEATURESSYSTEM REPORT
42 Simon & Schuster: A twice-told taleA warehouse control system and new technology is the hero at Simon & Schuster’s New Jersey distribution center.
SPECIAL REPORT
51 Productivity Achievement AwardsModern’s annual Productivity Achievement Awards honor companies that have made outstanding strides in improving operations through materials handling and related information systems.
PRODUCTIVITY SOLUTION
58 Lean and green palletsWith a new presswood pallet, Lincoln Electric is not only meeting European export requirements and streamlining its pallet inventory, it’s reaping sustainability benefits.
EQUIPMENT 101 SERIES: PALLET RACK
60 Behind the backbonePallet rack is a fundamental component that can maximize storage space and have a positive impact on organization, productivity and throughput in your facility.
SPECIAL REPORT
66 Reader survey: Conveyor technologyConveyors are the most used form of automation in today’s plants and distribution centers. Modern readers told us how they’re putting the technology to work.
60 Seconds with... George Prest
Modern Materials Handling ® (ISSN 0026-8038) is published monthly by Peerless Media, LLC, a Division of EH Publishing, Inc., 111 Speen St, Suite 200, Framingham, MA 01701. Annual subscription rates for non-qualifi ed subscribers: USA $119, Canada $159, Other International $249. Single copies are available for $20.00. Send all subscription inquiries to Modern Materials Handling, 111 Speen Street, Suite 200, Framingham, MA 01701 USA. Periodicals postage paid at Framingham, MA and additional mailing offi ces. POSTMASTER: Send address changes to: Modern Materials Handling, PO Box 1496, Framingham MA 01701-1496. Re-production of this magazine in whole or part without written permission of the publisher is prohibited. All rights reserved. ©2011 Peerless Media, LLC.
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MICHAEL LEVANSGROUP EDITORIAL
DIRECTOR
THIS MONTH IN MODERN
No one is a bigger advocate for online education than I am. In fact, we’ve built a major portion of Mod-
ern’s business around online media delivery, webcasts and virtual conferences that offer a highly valued learning experience that can be accessed from the comfort of your own facility—or most comfortable chair.
And while new media has carved out its niche in continuing education, the act of supplementing that experience with some old fashion, face-to-face interaction will never go out of style.
I realize that many readers have been grounded over the past two years due to budget cuts and the lack of precious time. Has it been a couple years since you’ve strolled a show fl oor, shook a few hands, saw some of the latest equipment in action, or had dinner with a long-time equipment vendor or old colleague?
Well, I’m going to suggest that you pack a bag for a few days and get to ProMat 2011 in Chicago (March 21-24).
The economic tide is turning, and our research is pointing to a renewed optimism in terms of materials handling investment. According to Modern’s 2011 State of the Industry Survey, the timing of this year’s show should certainly have the folks at the Material Handling Industry of America (MHIA), the host of the bi-annual event, smiling from ear to ear.
Our survey reveals that, while still a bit cautious; U.S. businesses are now looking to make more long-term investments in their materials handling operations and are con-siderably more optimistic about the future than just a year ago. In fact, slightly more than one-half (51%) told us that they’re
proceeding with needed/planned purchases this year; most signifi cantly, a hardy 22% say the current economic conditions are not dampening materials handling spending in any appreciable way.
That data should set the table for a rather active show fl oor. In fact, MHIA says it’s an-ticipating more than 700 exhibitors and is projecting close to 30,000 visitors. MHIA has sweetened the pot a little this year for those organizations that may be taking a closer look at robotic solutions inside their four walls. ProMat will be co-locating with Automate 2011, an event sponsored by the Automation Technologies Council (ATC), that highlights the latest robotic vision, motion control and automation technologies and systems.
And while it will be good to assess how the latest technology may be applied inside your operation, it would be worth your while to sit in on one of the more than 80 educational sessions that the MHIA has programmed over the four days. It never hurts to brush up on the basics or chat face-to-face with peers who are facing similar operational challenges.
It’s also a good time to spend some time with us. The entire Modern editorial staff along with a complement of contributing editors will be covering the show fl oor for the ProMat Show Daily, the print and online source for keeping you up to date on all the activities surrounding the four-day event.
I suggest you dig into the closet and dust off your suitcase. What you might fi nd in Chicago next month could not only revolutionize your operations, but help you reconnect face-to-face with the people who drive innovation in our industry.
The importance of being there
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Visit Us at Booths 3603 & 3612
To learn more about the Dematic Multishuttle visit ProMat booths 3603 & 3612 or www.dematic.us or call 1-877-725-7500.
The Dematic Multishuttle solution is an all new way to assemble orders. It is the highly efficient engine that provides precise load sequencing at higher rates, in less space, with more operational flexibility. Multishuttle is ideal for supplying product to piece pick order fulfillment modules or mixed case pallet building operations; it can also be applied as a short term buffer storage system or as a parts support system for production operations.
Dematic Multishuttle re-defines order fulfillment and warehouse logistics 10 ways:
Increased throughput: 4–7 times greater than conventional storage systems
High utilization: Feeds workstations with high rates to keep workers fully utilized
Smaller footprint: Fewer aisles required to obtain same rate
More layout options: Fits into overhead spaces, under/over obstructions, best cube utilization
Precise sequencing: Presents loads to pick stations or palletizers in exact sequence
Range of load types: Flex option accommodates various load sizes
Energy efficient: Low voltage carrier uses less energy; quiet operating
Redundancy with back-up: Identical carriers provide duplicate service; carriers are interchangeable
Access to stock: Walkways in the rack aisles allows manual back up picking
Scalability: Add more carriers in future to provide more throughput
New Order Fulfillment EngineElevates Warehouse Performance
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IT SEEMS AS IF the Material Han-dling Industry of America (MHIA, www.mhia.org), sponsor of ProMat 2011, had a premonition of this winter’s wrath when it moved the bi-annual industry event this year from snowy January to March in Chicago.
ProMat, the materi-als handling industry’s premier trade show and educational conference, will be held at McCor-mick Place South from March 21 to 24, and offi -cials are getting ready to welcome nearly 30,000 visitors.
Attendees will fi nd more than 700 exhib-its, two keynotes, two educational tracks and 80 educational ses-sions spread over the four days. In addition, registered attendees not only gain full access to ProMat, but also free en-try into Automate 2011, held across the hall in McCormick Place North.
Like ProMat, Automate
(formerly the International Robots, Vision & Motion Control Show) is held just once every two years. Sponsored by the Automation Technologies Council (ATC)—and its trade associa-tions Robotic Industries Association (RIA), Automated Imaging Association
(AIA) and Motion Control Association (MCA)—Automate will showcase the latest robotic, vision, motion control and automation technologies and systems.
MHIA and ATC brought the two shows together for the fi rst time to help visitors maximize their travel time and budget. Because of the logical fi t between the industries and their technologies, and the emergence of more robotics systems into materials handling practices, now seemed like a good time to co-locate, said John Nofsinger, CEO of MHIA.
“We’ve always known that the au-dience for the robotics and materials handling industries are very compat-
m m h . c o m MODERN MATERIALS HANDLING / F E B R U A R Y 2 0 1 0 9
Company Briefi ngs | Bob Trebilcock CHEP aims to build the better pallet www.mmh.com/blogs
Di@blogbest of Modern’s blogs
BY NOËL P. BODENBURG, EXECUTIVE MANAGING EDITOR
TRADESHOWS
ProMat 2011 ready for 30,000 attendeesINDUSTRY TRADESHOW AND EDUCATIONAL CONFERENCE WILL ALSO OFFER ACCESS TO AUTOMATE 2011.
MMH1102news.indd 9 2/9/11 12:27 PM
ible and, because there is little overlap in the member-ships of our two organizations, very few exhibitors had to choose in which event to exhibit,” he added.
With two shows being hosted in one location, offi cials decided to have not one, but two keynote addresses. The fi rst runs Monday morning and features Tom Ridge, the fi rst U. S. Secretary of Homeland Security. During the presentation, “Fortune Favors the Brave: The Net Gain of Supply Chain Security in a Risk-Based World,” Ridge will examine the inextricable link between security and prosperity for the global supply chain.
On Tuesday, the second keynote presentation, “The Development of Robonaut 2: A Story of Government-Industry Collaboration and Technology Transfer for the Next Generation of Robotic Solutions,” will feature speakers from NASA and General Motors. The two or-ganizations will share insights into how they continue to work together to accelerate the development of the next generation of robots and related technologies for use in both the automotive and aerospace industries.
Co-located events
In addition to Automate, other organizations affi liated with the materials handling and robotics industries have seized the opportunity to host events during these four days. These include the 42nd International Symposium on Robotics (fully integrated with Automate) and the 2011 Industrial Crane & Hoist Conference (co-located with ProMat).
Further, associations and affi liated groups are host-ing gatherings to give show visitors the chance to meet and learn more about topics specifi c to their industry in private rooms at McCormick Place. These include WERC Council of Chicago, The Material Handling Equipment Distributors Association (MHEDA), and the National Re-newable Energy Lab (NREL).
EducationBeyond the 700 exhibits on the show fl oor, ProMat offers numerous ways for you to learn something new. Eighty free educational sessions will be located in the Knowledge Center running from 10:30 a.m. to 4:45 p.m. Monday and Tuesday, and on Wednesday from
ProMat 2011 FactsName of Event: ProMat 2011
Event Sponsor: The Material Handling Industry of America
Event Dates: March 21-24, 2011
Event Location: McCormick Place South, Chicago
Registration: www.ProMatShow.com
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“The on-fl oor seminars are presented by industry ex-perts in materials handling and logistics solutions,” says Terri Heisey, manager of conference programs for MHIA. “It’s a great opportunity for attendees to be educated on the latest technologies from exhibitors, industry groups and research institutions.”
ProMat will also feature two half-day educational tracks that will provide in-depth coverage on supply chain career development and sustainability.
On Tuesday, from 1 p.m. to 4:15 p.m., a series of presentations and panel discussions will examine “The People Side of the Supply Chain.” This track will take a close look at how companies can succeed at leading the people who keep the supply chain moving. In these ses-sions, details will be shared about a variety of available resources that will help keep people interested, engaged and committed to a supply chain career and to your company.
On Wednesday, from 1 p.m. to 5 p.m., Steve Thomas of TV’s “This Old House” and “Renovation Nation” will be both speaker and host of several presentations dis-cussing “Sustainability, the Supply Chain and Their Future Together.” This speaker series will examine what it takes to start injecting sustainable practices into the supply chain, what is working today and what a sustainable sup-ply chain might look like in 2030.
Show FloorWith the economy slowly rebounding, exhibitors who chose to have a presence at the show will be in prime position to help a crowd of attendees that Nofsinger says has come prepared to buy.
“They’re coming to make specifi c, selected purchases, as opposed to just an introduction to new technologies,” he notes. Topping the must-see lists of most show visitors are solutions that enhance productivity, promote sustain-ability, and improve ergonomics as the workforce of the future both ages and shrinks in size.
“Companies spent the last two years postponing major expenditures as they worked to lean everything down in order to live to fi ght another day,” MHIA’s Nofsinger says. “Now, attendees are coming to equip and retool existing facilities to make them more productive so that as business starts to fl ow they can take advantage of the economic recovery.”
In addition to solidifying purchasing plans as they stroll the ProMat show aisles, attendees will discover new solutions to streamline operations and improve visibility, maximize effi ciency and fl exibility, cut costs and speed time to market. Exhibits from industry, commerce and government will be showcased throughout the 300,000 square foot show fl oor.
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WHAT HAPPENS WHEN you combine the No. 1 provider of voice recognition solutions with the No. 3 provider of au-tomatic data capture solutions? That’s a question Intermec and Vocollect
will begin to answer over the coming months and years. Last month, Inter-mec announced that it has entered into a defi nitive agreement to acquire Vocollect for $190 million in cash.
Intermec was No. 3 on Modern’s 2010 list of the Top 20 suppliers of automatic data capture solutions by revenue, while Vocollect was No. 14. Intermec has not announced its com-plete 2010 results just yet, but based on estimates, the combined com-panies will have in excess of $795 million in revenue for 2010—enough to give Zebra Technologies a run for the No. 2 spot behind Motorola.
In a press release, Intermec laid out some of the rationale for the combined companies:
• The transaction will expand Intermec’s product and application offerings in the warehouse space.
• It establishes Intermec as a player in the fast growing area of voice in industrial applications.
• Finally, both Intermec and Vocollect gain access to expanded market channels, customer bases and partner networks.
Earl Thompson, Intermec’s senior vice president of mobile business solutions, expanded on the release. The acquisition, he said, will further Intermec’s corporate strategy to be a much stronger player in the ware-house. He also believes there are real opportunities for voice to expand, both geographically into new ter-ritories and markets, and in how the technology is applied.
“Clearly, there’s an adoption opportunity for voice in emerging markets in Latin America and Asia,” he said. “But we also think North America is an under-penetrated mar-ket. Voice is only in 10% to 15% of facilities, and it’s mostly focused on picking applications. We think voice is still an early and disruptive tech-nology that can be applied to more workfl ows beyond picking.”
The acquisition also suggests that voice may be ready to evolve from a point solution—one that is installed by the voice solution provider—to a larger, integrated data collection solu-tion that integrates with other modes of data collection, said David Krebs, director of the mobile and wireless
TECHNOLOGY
Behind Intermec’s acquisition of Vocollect
MMH1102news.indd 14 2/9/11 12:27 PM
practice at VDC Research: “We think there a lot of greenfi eld opportunities for voice as we enter this emerging wave of multi-modal applications that combine voice with other technologies.”
Krebs added that he will be watching to see how Intermec’s ADC competi-tors respond. “The acquisi-tion strengthens Intermec’s warehouse portfolio,” he said. “If they can integrate Vocollect into their port-folio, it will be interesting to see how Motorola, LXE and Psion respond. They all compete indirectly against Vocollect and now they’ll be
competing directly against Intermec as well.” For now, Vocollect solutions will be offered by Inter-
mec; but, Vocollect will continue to go to market with proprietary hardware and software solutions that are available to end users that may have someone else’s hardware in place for bar code scanning and mobile com-puting. “At this point, there’s no reason to change that go-to-market strategy,” said Thompson.
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ECONOMY
ISM’s January manufacturing data shows strong momentum to begin 2011BUILDING ON THE SUCCESS of a solid 2010, the manu-facturing sector is off to a promising start in 2011, ac-cording to the Institute of Supply Management’s January Manufacturing Report on Business.
The ISM reported that the index it uses to measure the manufacturing sector—also known as the PMI—was 60.8 in January, which is 2.3% of December’s 58.5 and marks the highest level the PMI has seen since May 2004’s 61.4. Any reading 50 or higher represents economic growth, and January is the 20th consecutive month economic growth has occurred, according to the report. January’s strong showing also marks the sixth straight month of month-over-month growth in the manufacturing sector, according to the ISM.
“The continuing strong performance is highlighted as January is also the sixth consecutive month of month-over-month growth in the sector,” said Norbert J. Ore,
Vist us at booth 1726
MMH1102news.indd 15 2/9/11 12:27 PM
16 F E B R U A R Y 2 0 1 1 / MODERN MATERIALS HANDLING m m h . c o m
CPSM, C.P.M., chair of the Institute for Supply Management Manufac-turing Business Survey Committee, in a statement. “New orders and production continue to be strong, and employment rose above 60% for the fi rst time since May 2004. Global demand is driving commodity prices higher, particularly for energy, metals and chemicals.”
In the January report, New Orders at 67.8 were up 5.8%, and Produc-tion at 63.5 was up 0.5%. Employ-ment at 61.7 was up 2.8%. Inven-tories were up 0.6% at 52.4, and Customers’ Inventories at 45.5 saw a 5.5% gain. Backlog of orders was up 11.0% at 58.0, and Prices at 81.5 rose 9.0%.
Ore told Modern in an interview that this report is part of a larger trend pointing to positive economic activity in the manufacturing sector. He added it comes on the heels of a strong 2010, when PMI averaged 57.3, marking the
third highest PMI in the last 20 years next to 1994 and 2004.
“Part of the reason we saw a strong January was that the consum-er showed up for the holiday season,
which helped tremendously,” said Ore. “The other thing that helped was the clarity that was achieved over the tax code. People hit Janu-ary with expectations for a good year and continuing growth, and the gen-eral climate was greatly improved.”
With customers’ inventories up
5.5%, the report’s respondents noted that they felt this number remains too low. Ore said the inven-tory issue is one of the more diffi cult things to analyze during this eco-nomic recovery.
The reason for this, he said, is that there have been several months of growth in inventories, but it is obvious that manufacturers reduced inventory so dramatically that they have spent 2010 trying to catch up.
“I would take the most recent reading on customers’ inventories to indicate that supply chains are getting close to the level that they would like to see where they are getting more comfortable with their inventory level,” said Ore. “I think we will also see minor growth in inventories on a monthly level going forward, with people dropping their inventories back to more of a busi-ness as usual level.”
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“New orders and
production continue to be
strong, and employment
rose above 60% for the first
time since May 2004.”—Norbert Ore, chair of the ISM Manufacturing Business
Survey Committee
MMH1102news.indd 16 2/9/11 12:27 PM
both above 60, Ore said that the strength in manufacturing being car-ried into the fi rst quarter—even if the other two months of the fi rst quarter are not as strong as January—the fi rst quarter and fi rst half of the year look to be strong, as opposed to previous expectations indicating that true growth would not occur until the second half of the year.”
“Our initial expectations are not nearly as strong as these numbers are,” said Ore. “I think we will see a strong fi rst quarter, which could carry the fi rst half of the year. We have had a lift in confi dence, but I think there is still a lack of confi dence in the federal government in dealing
with defi cits. And that could wear thin as we get deeper into the year, as people could have concerns about the ability of the Congress to deal with budget issues and could be a constraint in the second half of the year. But we are off to a very good start to the year although it has to level off at some point. If we average a PMI of 53.5 to 54 for the year, we would be very happy.”
Ore said these positive manufac-turing cycles generally last from 70 to 110 months, and there is an expecta-tion that with 18 months of manu-facturing growth in the books, it is realistic to expect another 12 at this point through the end of 2011.
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Solutions
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blog@wayExcerpts from executive editor Bob Trebilcock’s bloggo to... www.mmh.com for complete posts
Is a hybrid AGV in your futureIf you see hybrid AGV and think of the Prius, you’re not alone. A press release touting a new hybrid AGV had me thinking the same thing. However, that’s not what Egemin has in mind, according to Dave Noble, the AGV-maker’s marketing com-munications director. The hybrid AGV Egemin is touting, and will have on display at ProMat, is a vehicle with dual functionality: an off-the-shelf man-aboard lift truck that can operate manually, like a traditional lift truck, or in automatic mode as a laser-guided AGV...
Outrunning the bear or how SAP approaches SCEYou’ve heard the old joke. Two hunters are in the woods when they startle a big old grizzly bear. As the bear starts to charge, one hunter says: “I sure hope we can outrun that bear.” The other hunter says: “I don’t have to outrun the bear. I just have to outrun you.”
That story says a lot about how SAP, No. 1 on Modern’s list of the Top 20 providers of supply chain management software, is approach-ing the supply chain execution market today, according to Karen Peterson, vice president of supply chain execution solution manage-ment for SAP...
The next wave of supply chain innovationVenkat Rajaji has a theory. The next big push for technology in the supply chain could come about because of government regulation. “If you look back historically, a number of technology changes have been trig-gered by compliance to government regulation,” says Rajaji. “Think about Y2K. Think about Sarbanes–Oxley”
Rajaji is global product manager for Infor’s product lifecycle man-agement division. The government regulation he’s eyeing this time is the recently passed Food Safety Mod-ernization Act...
MMH1102news.indd 17 2/9/11 12:27 PM
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mmh.com Modern Materials Handling / F e b r u a r y 2 0 1 1 19
Statistics on the amount of product damaged from lift truck attachments and clamps are hard to pinpoint, but the tally is undoubtedly in the hundreds of
thousands of dollars a year, according to Brad Vandehey, product manager for attachment manufacturer Cascade (www.cascorp.com).
In recent years, advances in on-board lift truck comput-ing and aftermarket attachments have added brains and finesse to the brawn of the warehouse workhorse. Still, load clamping remains a perennial source of shrinkage. Lift trucks have always preferred the blunt technique of a spatula over the delicacy of a thumb and forefinger, but new force control clamp offerings aim to bestow lift truck operators with the precision needed to cut product loss and boost productivity.
The problem is most notable in operations where loads of variable weight are handled, according to Vande-hey. A 2,800-pound pallet might look nearly identical to one that weighs closer to 400 pounds, and the operator might assume the same clamp force will work for both.
“If they’re going from a stack of eight washers to a single unit, that one washer could be in trouble,” says Vandehey. “The operator should not have to guess how much force to apply.”
When working to identify the sources of shrinkage, Vandehey is careful to distinguish between poor driver habits and the limitations of the machinery. Even if a driv-er has a pretty good idea of how much force to apply, the mechanisms for applying that force cannot be accurately controlled by the driver. In electric lift trucks, the mo-tor spools up at such a speed that it can get away from even an experienced driver, Vandehey says. With variable clamp force pressure regulators that offer a stick-shift interface, operators must learn the gears and use them.
With force control technology, the operator is taken out of the equation. Each load is automatically weighed and no more than the needed force is applied. In the near future, radio frequency identification tags (RFID) might in-tegrate with a warehouse management system to provide even more specific information about proper load han-dling—again without any reliance on the operator.
When force control was implemented at one paper facility, the manager informed Vandehey that the differ-ence was immediate.
“After it was installed, he told me, ‘One day the op-erators were crushing rolls, and the next day they were not,’” Vandehey recalls. “The plant manager said ‘it was intuitively obvious that we are saving money.’”
At an estimated retrofit cost of $5,000 to $6,000 for some models of automatic force control technology, Vandehey estimates the savings could be easily recouped within a year, and warehouse managers won’t be the only ones happy to avoid damaged goods.
“How hard is it for the average shopper in the supermarket to walk past the crumpled paper prod-uct in favor of the one that looks like it hasn’t been crushed?” asks Vandehey. “Hopefully one day that won’t be a problem.” M
Handle with careForce control attachments aim to take the guesswork out of clamping.
lift truck TIPS
By Josh Bond, Contributing Editor
Josh Bond is a contributing editor to Modern and can be reached at [email protected].
MMH1102_LiftTruckTips.indd 19 2/9/11 1:31 PM
SUPPLY CHAIN INNOVATION STARTS AT PROMAT® 2011 REGISTER TODAY! www.ProMatShow.comwww.ProMatShow.com
Find us on:
From March 21-24, 2011 the material handling and logistics industry will showcase the latest manufacturing, distribution and supply chain solutions at ProMat 2011.
Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions. Choose from 80 educational sessions that deliver valuable insights into the latest trends, technologies and innovations.
ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you:
• Streamline your operations and improve visibility• Maximize effi ciency and fl exibility• Cut costs• Speed time to market• Reduce your carbon footprint
Register Today For ProMat 2011!Find free registration, detailed exhibitor information, educational session details, show news and your customized My ProMat Show Planner at www.ProMatShow.com or call 800-446-2622 or 704-676-1186.
www.ProMatShow.comSOLUTIONS THAT MAKE THE SUPPLY CHAIN WORK®
Sponsored by:
Collocated with ProMat 2011
ProMat 2011 Keynotes
Monday, March 21 at 8:45-9:45 amFortune Favors the Brave: The Net Gain of Supply Chain Security in a Risk-Based World
Tom RidgeFirst Secretary of Homeland Security
Terrorism, natural disasters, vendor issues, and geopoliticalinfl uences can put issues such as supply chain security, cross-border collaborations, and security investment at the forefront of every proactive business agenda. Duringthis keynote, Secretary Ridge will share his views of today’s risk-centric environment and how to minimize those risks in favor of greater resiliency and security across your global supply chain.
Tuesday, March 22 at 8:45-9:45 am The Development of Robonaut 2: A Story of Government-Industry Collaboration and Technology Transfer
Learn how NASA and General Motors are working together to accelerate development of the next generation of robots and related technologies for use in the automotive and aerospace industries. This partnership led to development of Robonaut 2 (R2), a state-of-the-art dexterous humanoid robot built and designed at NASA Johnson Space Center.
ProMat 2011 Educational Tracks
Tuesday, March 22 at 1:00-4:15 pmThe people side of the supply chain
This full afternoon track takes a close look at how you can be successful at leading the people who keep your supply chain moving. Learn how to keep your workforce interested, engaged and committed to a supply chain career and to your company.
Topics include:
How to capitalize on diversity in the workforce Dan Boos, Boos Consulting Services
Preparing people for the workforce Kimberly Ellis, Virginia TechJustin Love, SchlumbergerKathy DePiro, Greater Altoona Career & Tech CenterCraig Eckenrode, Stevens Co. Inc.What a peer learning group can do for your careerJosh Dennie, OptimaxBruce Peters, WCEOHQ Radio
My aspirations: 20-somethings sound off on what makes them tick Kim Absil, Sears HoldingsJosh Dennie, OptimaxJustin Love, SchlumbergerCraig Eckrenrode, Stevens Co. Inc.
What are you worth and why? Mitch Mac Donald, DC VelocityDave Blanchard, Material Handling & Logistics
Keeping top talent as the economy recoversDan Boos, Boos Consulting Services
Wednesday, March 23 at 1:00-5:00 pmSustainability, the supply chain and their future together
In this full afternoon session, a wide range of speakers will detail how to get started, what works today, and what a sustainable supply chain will look like in a ouple of decades.
Topics include:
The green supply chain starts at home Steve Thomas, Emmy-award winning television host of “This Old House” and “Renovation Nation”
Top trends in industrial sustainability Gary Forger, Material Handling Industry of America
How LEED certifi cation cuts costs and improves effi ciencies Michael G. Englehard, ProLogis
Walmart’s plan for sustainable distributionVirginia Garbutt, Walmart Canada
A look at the sustainable supply chain of 2030 Benoit Montreuil, Université Laval
What you can do to green the supply chainSteve Thomas
Register Today For ProMat 2011!Find free registration, detailed exhibitor information, educational session details, show news and your customized My ProMat Show Planner at www.ProMatShow.com or call 800-446-2622 or 704-676-1186.
www.ProMatShow.com
Dan Boos
Steve Thomas
9626-MHIA ProMat_MMH_SpreadAd.indd 1-2 1/25/11 1:16 PMMMH0211_Ads.indd 20 2/3/11 10:19 AM
SUPPLY CHAIN INNOVATION STARTS AT PROMAT® 2011 REGISTER TODAY! www.ProMatShow.comwww.ProMatShow.com
Find us on:
From March 21-24, 2011 the material handling and logistics industry will showcase the latest manufacturing, distribution and supply chain solutions at ProMat 2011.
Explore over 700 exhibiting companies featuring cutting-edge equipment and systems solutions. Choose from 80 educational sessions that deliver valuable insights into the latest trends, technologies and innovations.
ProMat 2011 is the one show where you will see in action the latest solutions and innovations the industry has to offer and meet the leading providers face-to-face to help you:
• Streamline your operations and improve visibility• Maximize effi ciency and fl exibility• Cut costs• Speed time to market• Reduce your carbon footprint
Register Today For ProMat 2011!Find free registration, detailed exhibitor information, educational session details, show news and your customized My ProMat Show Planner at www.ProMatShow.com or call 800-446-2622 or 704-676-1186.
www.ProMatShow.comSOLUTIONS THAT MAKE THE SUPPLY CHAIN WORK®
Sponsored by:
Collocated with ProMat 2011
ProMat 2011 Keynotes
Monday, March 21 at 8:45-9:45 amFortune Favors the Brave: The Net Gain of Supply Chain Security in a Risk-Based World
Tom RidgeFirst Secretary of Homeland Security
Terrorism, natural disasters, vendor issues, and geopoliticalinfl uences can put issues such as supply chain security, cross-border collaborations, and security investment at the forefront of every proactive business agenda. Duringthis keynote, Secretary Ridge will share his views of today’s risk-centric environment and how to minimize those risks in favor of greater resiliency and security across your global supply chain.
Tuesday, March 22 at 8:45-9:45 am The Development of Robonaut 2: A Story of Government-Industry Collaboration and Technology Transfer
Learn how NASA and General Motors are working together to accelerate development of the next generation of robots and related technologies for use in the automotive and aerospace industries. This partnership led to development of Robonaut 2 (R2), a state-of-the-art dexterous humanoid robot built and designed at NASA Johnson Space Center.
ProMat 2011 Educational Tracks
Tuesday, March 22 at 1:00-4:15 pmThe people side of the supply chain
This full afternoon track takes a close look at how you can be successful at leading the people who keep your supply chain moving. Learn how to keep your workforce interested, engaged and committed to a supply chain career and to your company.
Topics include:
How to capitalize on diversity in the workforce Dan Boos, Boos Consulting Services
Preparing people for the workforce Kimberly Ellis, Virginia TechJustin Love, SchlumbergerKathy DePiro, Greater Altoona Career & Tech CenterCraig Eckenrode, Stevens Co. Inc.What a peer learning group can do for your careerJosh Dennie, OptimaxBruce Peters, WCEOHQ Radio
My aspirations: 20-somethings sound off on what makes them tick Kim Absil, Sears HoldingsJosh Dennie, OptimaxJustin Love, SchlumbergerCraig Eckrenrode, Stevens Co. Inc.
What are you worth and why? Mitch Mac Donald, DC VelocityDave Blanchard, Material Handling & Logistics
Keeping top talent as the economy recoversDan Boos, Boos Consulting Services
Wednesday, March 23 at 1:00-5:00 pmSustainability, the supply chain and their future together
In this full afternoon session, a wide range of speakers will detail how to get started, what works today, and what a sustainable supply chain will look like in a ouple of decades.
Topics include:
The green supply chain starts at home Steve Thomas, Emmy-award winning television host of “This Old House” and “Renovation Nation”
Top trends in industrial sustainability Gary Forger, Material Handling Industry of America
How LEED certifi cation cuts costs and improves effi ciencies Michael G. Englehard, ProLogis
Walmart’s plan for sustainable distributionVirginia Garbutt, Walmart Canada
A look at the sustainable supply chain of 2030 Benoit Montreuil, Université Laval
What you can do to green the supply chainSteve Thomas
Register Today For ProMat 2011!Find free registration, detailed exhibitor information, educational session details, show news and your customized My ProMat Show Planner at www.ProMatShow.com or call 800-446-2622 or 704-676-1186.
www.ProMatShow.com
Dan Boos
Steve Thomas
9626-MHIA ProMat_MMH_SpreadAd.indd 1-2 1/25/11 1:16 PMMMH0211_Ads.indd 21 2/3/11 10:19 AM
22 F E B R U A R Y 2 0 1 1 / MODERN MATERIALS HANDLING mmh.com
ChicagoMarch 21-24, 2011
SHOW PREVIEW
PUTTING PRODUCTIVITYTO WORK
MMH1102_ShowPreview2.indd 22 2/9/11 12:21 PM
mmh.com Modern Materials Handling / F e b r u a r y 2 0 1 1 23
ProMat 2011, slated for March 21-24, will showcase more than 700 exhibits and include a comphrehensive educational conference. the event, to be held at McCormick Place in Chicago, will offer an array of products to help improve productivity at your company.
sHow HoursMonday 10:00 a.m. - 5:00 p.m.tuesday 10:00 a.m. - 5:00 p.m.wednesday 10:00 a.m. - 5:00 p.m.thursday 10:00 a.m. - 3:00 p.m.
agV converts to operator-guided forklift Morphing manual and automatic operations, a new hybrid automated guided vehicle allows an operator to interrupt automatic AGV operations, move product manually and then place the forklift back into fully automatic laser guidance mode. The vehicles are offered in two sizes—3,500- and 5,500-pound capacities—with lifting heights up to 23 feet. Typically interfacing with deep lane floor stacking, pushback rack, drive-in rack and standard racking, the vehicle features industrial lead-acid batteries, laser guid-ance and navigation, advanced laser safety systems, graphical touchscreen monitor, Windows OS and wire-less communications. Options include RFID readers, bar code scan-ners, 3D camera tech-nology, robotic battery exchange, automatic battery charging, mech-anism side-shift and sin-gle/double fork systems. egemin, 616-393-0101, www.egeminusa.com. Booth 2347.
scalable staging buffer for goods-to-person picking operationsGenerating up to seven times greater throughput in a smaller footprint than conventional storage systems, the Multishuttle staging buffer feeds workstations at high rates to keep workers fully utilized. The system is ideal for applications that require dynamic product sequencing to support goods-to-person order fulfillment, pick face replenishment, pallet-izing, and production buffers. Included are multiple levels of rack structure, carrier vehicles, conveyor and software. Each level of the rack structure includes input/output conveyor and a carrier vehicle that travels horizontally to access loads stored in the rack structure (typically totes or trays). An extraction device on each carrier vehicle accesses the loads in the rack. The system may be configured in a variety of layouts, including overhead spaces and under/over obstructions for the best cube utilization. dematic, 800-457-9783, www.dematic.us. Booth 3603 and 3612.
tilt-tray, cross-belt sorters offeredThe IntelliSort CB cross-belt and TT tilt-tray sorters for high-volume distribution centers, parcel hubs and fulfillment operations reliably handle sortation in high-capacity, high-speed sorting environments. Both cross-belt and tilt-tray tech-nologies are ideal for use in appli-cations with a variety of product sizes and shapes that require high throughput and accurate sortation. Compact and modular, the sorters
may be used in new construction or retrofit applications. intelligrated, 866-936-7300, www.intelligrated.com. Booth 2903.
Voice-directed software with graphical managementThe latest version of Jennifer VoicePlus software for voice-directed warehouse operations has been released. Included is the Engage manage-ment services console, an Internet application that provides a suite of graphical management tools to analyze and manage voice operations. Also offered is Mobile Engage, a smartphone/PDA-based application providing the same man-agement capabilities for mobile devices. This functionality enables managers to be on the warehouse floor without losing touch with critical operational information. The systems are ideal for use in grocery and foodservice, retail, medical products, industrial supply, and consumer product goods distribution. lucas systems, 724-940-7000, www.lucasware.com. Booth 3879.
MMH1102_ShowPreview2.indd 23 2/9/11 12:21 PM
Smart AGVs can be used in moving assembly linesSmartCart AGCs are flexible, low-cost automatic guided vehi-cles that can be used in assem-bly lines, to deliver pallets to and from stretch wrappers, roller conveyors and pallet-izers, or to move loads around a facility. The carts are guided by updated, easy-to-use software that accepts user-authored system changes and enables troubleshooting without outside assistance. For implementation in a continuous moving assembly line, an unlimited number of carts can be synchronized at a close distance, while traveling as slow as 6 feet per minute. Jervis B. Webb, 800-791-3092, www.jervisbwebb.com. Booth 2003.
Reinforced construction enhances vertical carousel’s reliabilityEngineered for enhanced reliability and uptime, the Avenger vertical carousel uses a patent-pending forging to reduce stress on structure components, plus double-reinforced arm assembly to provide extra strength and durability. Each carrier (shelf) has eight scissor arms to eliminate bending, tearing and breaking. A forging and roller attaches the arms to
the track, instead of traditional pin and roller assembly, to reduce stress and prevent sys-tem failure and machine damage. The carousel is offered in multiple models for light- to heavy-weight applica-tions, with warranties up to 10 years on some models. Sapient Automation, 800-639-5805 www.GetSapient.com/Avenger. Booth 4231.
24 F e b r u a r y 2 0 1 1 / ModeRn MAteRiAlS HAndlinG mmh.com
SHOW PREVIEW AS/RS single-mast crane lifts 220 pounds to 39 feetThe Mustang Evo automated storage and retrieval system for mini-load use is a single-mast crane with a maximum payload of 220 pounds and an optimum height of 39 feet. Features include lightweight construction based on aircraft concepts to reduce overall weight by 25% with a lighter mast with spe-cially rolled profiles, consistently adapted material thickness and high-strength bolted connections for increased stiffness. Further enhancements include improvements to the crane’s center of gravity, better distribu-tion of loads to the running wheels, and the elimination of drive motors at the top of the
machine for a reduction in maintenance and operational costs. tGW-ermanco, 231-798-4547, www.tgw-ermanco.com. Booth 612.
Robotic imaging, picking cell The Robo-Pick fully automatic picking cell compiles shipments from two to 20 articles in the correct quantity from a range of 5,000 to 50,000 articles in stock. The system combines 3D and 2D picture processing to identify products on a passing tray. Products in several layers or inclined position, jet-black articles, round products or asymmetric or beveled packages do not affect the vision system. Individual products do not need to be programmed into the system, which uses already existing alloca-tions of transport units and SKUs in automated warehouses to ensure that the customer receives the correct articles. Schaefer Systems, 800-876-6000, www.ssi.schaefer-us.com. Booth 2303.
Flexible WMS easy to installTo meet the logistics needs of any size warehouse, the EasyWMS warehouse management system is simple to install and requires minimal implementation time. Flexible enough to be used in facilities with varying levels of complexity, the WMS supports operating sys-
tems up to Windows 7. Multi-lingual technical support is offered. Features include the display of real-time statuses of stock levels, loca-tions, productivity and shipments for
increased warehouse performance, increased turnover ratios, opti-mized order preparation, improved online inventories, and reduced time needed for stock management. interlake Mecalux, 877-632-2589, www.interlakemecalux.com. Booth 2012.
MMH1102_ShowPreview2.indd 24 2/9/11 12:21 PM
mmh.com Modern Materials Handling / F e b r u a r y 2 0 1 1 25
stand-up counterbalanced lift truck The models 4150 and 4250 stand-up counterbalanced lift trucks han-dle load capacities from 3,000 to 5,000 pounds. For a smoother ride, the suspension adapts automatically to each operator’s weight while a cushioned floor mat isolates the driver from impact and vibration. Capable of performing right-angle stacking maneuvers in less total area, the three-wheel vehicles include a dual steer wheel, allowing one wheel to counter-rotate during turns for a shorter turn radius with reduced tire loading and steering friction. Visibility is enhanced with an angled front cover for a clear view of forks as they engage loads on the floor for more accurate handling and stacking. the raymond Corp., 800-235-7200, www.raymondcorp.com. Booth 3219.
independent transport robot, gantry case/layer robot featuredCapable of independently performing random origin to random destination transport, the ADAM intelligent mobile robot is ideal for moving work-in-process materials and finished goods in lean manufacturing and assembly applications. Missions are completed autonomously, navigating around fixed and moving objects, without guide wires, reflectors or transponders. A new gan-try robot based case and layer picking solution for automated operation in food, beverage and consumer products distribution facilities is also offered. This flexible, integrated system delivers cases exactly the desired sequence for automated mixed case palletizing or direct trailer loading at the dock. rMt robotics, 905-643-9700, www.rmtrobotics.com. Booth 3503 and 3821.
Move workers, loads with mezzanine platform liftTraveling from 8 to 18 feet, a line of rider mezzanine lifts is offered. Ideal for mov-ing workers with loads up one to two floors—or to high stages and mezzanines—the units include platforms rang-ing in size from 6 x 8 to 8 x 12 feet. advance lifts, 800-843-3625, www.advancelifts.com. Booth 2059.
laser bar code scanner debutsOffering enhanced coverage, ease of use and flexible connectivity options, the AccuLazr AL5010 laser bar code scanner uses modular components including scan head, mounting base, power supply and choice of interface modules. The unit is ideal for applications includ-ing pick modules, print and apply, routing, and sortation. Housed in a rugged IP65 enclosure, the scanner comes in five models and covers distances from 5 to 48 inches. Standard and high-density configura-tions are supported. Depending on the model, the device includes Ethernet-Ethernet/IP, RS232/422 serial ports, tach input and optional I/O modules with DeviceNet/Profibus plug-ins. accu-sort, 800-227-2633, www.accusort.com. Booth 2047.
Counterbalanced agV for warehousingDeveloped for automation of pallet movement in ware-houses, the counterbalanced automatic guided vehicle can pick up loads from the floor and block stack or inter-face with conveyors, stands and racking (standard single deep, pushback, flow through and drive-in). The ware-housing AGV uses flexible laser guidance and can use secondary guidance technology if required to navigate in narrow aisles and racking. The vehicle has a maximum capacity of 5,000 pounds and can be configured to han-dle single or double pallets. JBt, 215-822-4600, www.jbtc-agv.com. Booth 3915.
WMs tool for reconciliation of test and production data For easier reconciliation of test and production environments in multiple sites, the environ-ment manager tool has been added to the supplier’s 2010.2 warehouse management software release. The new tool propagates data between warehouse instances while checking for data differences without requiring duplicate configurations. By generating templates based on static information like locations and item definitions, the module reduces the time needed to go live with new warehouses or bring up new clients within those warehouses. Because it can be configured to ensure the user assembling the data cannot be the same user that propagates it to another system, the tool supports Sarbanes-Oxley compliance. redPrairie, 877-733-7724, www.redprairie.com. Booth 3676.
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26 F E B R U A R Y 2 0 1 1 / MODERN MATERIALS HANDLING mmh.com
A fAmily trAdition of growth, service And innovAtion
Give Your Heavy Pallets the Slip.
Material Handling
Ship more product per load with Rehrig’s weight, space and cost saving Slip Sheets.Ship more product per load with Rehrig’s weight, space and cost saving Slip Sheets.Ship more product per load with Rehrig’s weight, space and cost saving Slip Sheets.
Rehrig co-extruded Slip Sheets are a cost-effective alternative Rehrig co-extruded Slip Sheets are a cost-effective alternative to pallets. Impervious to moisture, high tensile strength plastic to pallets. Impervious to moisture, high tensile strength plastic provides added tear resistance making them the perfect provides added tear resistance making them the perfect replacement for fiber or corrugated sheets, as well.replacement for fiber or corrugated sheets, as well.
Available in standard or custom sizes, Rehrig Slip Sheets provide Available in standard or custom sizes, Rehrig Slip Sheets provide superior slide resistance, keeping goods securely in place. Manufactured superior slide resistance, keeping goods securely in place. Manufactured superior slide resistance, keeping goods securely in place. Manufactured from nearly 100% recycled material, each sheet is also 100% recyclable.from nearly 100% recycled material, each sheet is also 100% recyclable.from nearly 100% recycled material, each sheet is also 100% recyclable.
Beyond the sale, Rehrig can help you develop a customized re-use Beyond the sale, Rehrig can help you develop a customized re-use Beyond the sale, Rehrig can help you develop a customized re-use or buy-back program, further lowering your average cost per trip.buy-back program, further lowering your average cost per trip.
Phone: (800) 546-4993
Email: [email protected]
Web: www.rehrigpacific.com
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Call us for more information about:Call us for more information about:
Tier sheets, Liner sheets, Layer sheets, Tier sheets, Liner sheets, Layer sheets, Cap sheets, Divider sheets, Pallet pads and Separator sheets
Come see us at ProMatBooth #3526
SHOW PREVIEW
Plastic holders for slotted bins protect labelsTri-Dex label holders for standard plastic bin label slots are made of clear PVC. Fabricated in a tri-fold configuration, the
holders seal and protect the label. Printed labels slide into the holder and snap in place with-
out adhesive backing. The holders are offered five popular sizes to retrofit most standard bins. Laser inserts are included with printing instructions. A single pack-age includes 25 holders. Aigner Index, 800-242-3919, www.aignerindex.com. Booth 1914.
Mini-load AS/RS includes two stacker cranes per levelThe Duosys mini-load automated storage and retrieval system includes tuning con-trol technology. This design ensures that its two storage/retrieval machine stacker cranes can function in the same aisle without interference. The units move past each other to perform storage and retriev-al operations. The system can be laid out in two levels so that four SRMs operate simultaneously on the same rack, produc-ing throughput of up to 2,200 cases per hour. Daifuku America, 866-414-2057, www.daifukuamerica.com. Booth 2003.
Expanded pallet jack line A new line of pallet jacks ranges in capac-ity from 2,200 to 10,000 pounds, with widths from 16 to 43 inches, and fork lengths from 23 to 96 inches. Where required in pharmaceutical, food or other
applications, galvanized and stainless steel jacks are available. Also included in the line are straddle, high-rise scissor, low profile and weigh scale jacks. The trucks feature fully serviceable pumps, heavy-duty steel frames and fully adjust-able push rods. Options include automo-tive brake attachments, load backrests and a choice of wheel configurations and materials. Clark Material Handling, 866-252-5275, www.clarkmhc.com. Booth 2019.
Ergonomic workbenches, customizable A line of ergonomic modular work-benches and related products and acces-sories can be customized for specific needs, including enhanced production and a reduction in repetitive motion. The complete product line includes basic workbenches, packaging and mailroom workbenches, computer stations and work surfaces. For further configuration to meet unique application require-ments, accessories include adjustable metal shelves, footrests, louvered pan-
els, modular drawer systems, pull-out keyboard rests, tool balancers as well as torque arms. Pro-Line, 800-739-9067, www.1proline.com. Booth 305.
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Need to DOUBLE Storage capacity? Westfalia’s AS/RS can fit into
existing buildings only 20’ high
Need to PICK Faster?Westfalia’s Savanna.NET® WMS
provides fast, efficient, & accurate order picking at an affordable price
Westfalia Technologies, Inc.717-764-1115 • 800-673-2522www.WestfaliaUSA.com
OUR INNOVATIONYOUR SOLUTION
3-D Visualization
WMS Demo @
ProMat 2011
Booth # 3926
Automated Storage & Retrieval Systems (AS/RS)
Savanna.NET® Warehouse Management Software (WMS)
mmh.com Modern Materials Handling / F e b r u a r y 2 0 1 1 27
two-toned bins for effective inventory controlOffered as a low-cost alternative to high-end inventory control systems, a line of
indicator bins includes two colors in one unit. Formed with a bi-color mold to achieve a two-toned bin, the units simplify visual
recognition when supplies need to be replenished. They are stocked with a divider in place to designate volume for inventory reserve, and picked from the blue side until reaching the divider. The bins are then flipped to the orange reserve side to visually indicate low inven-tory levels and the need for replenish-ment. akro-Mils, 800-253-2467, www.akro-mils.com. Booth 1219.
image-based bar code reader The DataMan 500 image-based bar code reader uses custom software to achieve higher read rates by processing the 1D bar codes that laser readers cannot read, including damaged, distorted, blurred, scratched, low height and low contrast
codes. It captures images at up to 1,000 frames per second and is capable of reading codes in any orientation. The reader allows users to see what the reader sees on a monitor or through image archiving for later review. Cognex, 508-650-3000, www.cognex.com. Booth 768.
Collapsible plastic containerOffered in two sizes—48 x 45 x 26.5 and 48 x 45 x 34 inches—BV4845 BulkPak containers stack securely when full and collapse when empty for reduced trans-portation costs and condensed storage. The reusable containers fit 84 filled bins per inbound truckload and 252 collapsed bins per return truckload. Features include improved shipping density with a higher fill line that allows for more product per bin, a replaceable bottom stringer that reduces replacement cost of full base, and optimized spring-loaded latches. orbis, 888-307-2185, www.orbiscorporation.com. Booth 1803.
Forklift fuel cells, hydrogen refueling productsThe PowerEdge hybrid fuel cell system replaces standard lead acid batteries in electric lift trucks, and the PowerTap hydrogen generator and refueling station provides a low-emis-sion, cost-effective source of fuel from natural gas. Delivering quick refueling in less than 2 minutes, the systems produce consistent voltage throughout a shift, gen-erating up to 10% gains in productivity. nuvera Fuel Cells, 617-245-7500, www.nuvera.com. Booth 1226.
repair damaged rack legs For rack repair, the high strength Elite vertical leg kit is offered. The patented system is engineer-certified to guarantee high resistance to future impacts. Fully bolted, the engineered system anchors to concrete flooring with three 0.75-inch anchors. Mac rak, 815-723-7400, www.macrak.com. Booth 1277.
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LM MMH Template.indd 1 1/27/11 9:43 AM
Aigner Index Inc.218 MacArthur AvenueNew Windsor, NY 12553Tel:1.800.242.3919Email: [email protected]: 845.562.2638www.aignerindex.com
Aigner. Look to the Leader in LabelHolders.Aigner has the solution for most every
labeling need: Famed Hol•Dex® on
shelves, bins, drawers. Hi-Lo on
shelving above or below sight-lines.
Wire•Rac™ on wire shelving.
Magnetic Cardholders for instant
adhesion on metal. SuperScan™ for
scanable display on pallet racks.
Open•Edge™ for easy label
insertion on industrial shelving.
Write-On magnetic tags for
use with wet-erase markers. These
quality products assure you easy-read
identity with long-life durability. All
paper inserts are now laser ink-jet
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Hol•Dex
Hi-Lo
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SHOW PREVIEW
Fit 315 collapsed containers into trailerIdeal for applications including manufac-turing, plastic packaging products, food processing, dry goods and lightweight plastic components, the Maximizer reus-able, collapsible plastic container holds
Fast battery charging from high frequency systemUsing high frequency technology, eMax HF fast charger provides high charger efficiencies at lower operational costs, with high power factors to reduce AC
line draws and mini-mize infrastructure investment. Compact, the charger’s small footprint frees up floorspace. It is always connected and fully networked, with a wire-less communications interface for real-time
battery and charger fleet management. EnerSys, 800-538-3627, www.enersys.com. Booth 1203.
Control, monitor overhead cranes The LRC- M1 wireless control system for electrical overhead traveling cranes can control up to four motions with two ergo-nomic, multi-axis joystick controllers. The trolley/hoist selector, two auxiliary push buttons and toggles are mounted on an impact-resistant housing. The system is enhanced by enterprise software to com-municate wirelessly and bi-directionally with all fixed or mobile assets on a near real-time basis using either the IP-based cellular networks, 802.11, or both. Cattron Group, 724-962-3571, www.cattrongroup.com. Booth 1859.
up to 1,000 pounds. It features a 48 x 40 x 41 inch footprint, and folds to allow eight collapsed boxes to occupy the area of one assembled unit for a return ratio of 315 folded containers in a 53-foot trailer. The container can be set up or folded down in minutes and weighs 30% less than other plastic reusable alterna-tives. Buckhorn, 800-543-4454, www.buckhorninc.com. Booth 1219.
Palletizer redesigned for better ergonomicsFor enhanced ergonomics, the PalletPal level loader has been redesigned with a new, smaller base that permits the operator to step closer to the platform for faster, safer and easier loading and unloading of pallets. Heavy-duty springs automatically lower or raise a pallet load (from 400 to 4,500 pounds) as weight is added or removed, maintaining the top layer of stacked containers at a convenient height. A turntable ring, or optional turntable platform, at the top of the equipment allows the load to spin so the operator remains in the same spot throughout the loading or unloading process. Operating without power and maintenance free, the unit includes fork pockets at the base for easy relocation. Southworth, 207-878-0700, www.south-worthproducts.com. Booth 403.
MMH1102_ShowPreview2.indd 28 2/9/11 12:22 PM
LM MMH Template.indd 1 1/27/11 9:43 AM
Aigner Index Inc.218 MacArthur AvenueNew Windsor, NY 12553Tel:1.800.242.3919Email: [email protected]: 845.562.2638www.aignerindex.com
Aigner. Look to the Leader in LabelHolders.Aigner has the solution for most every
labeling need: Famed Hol•Dex® on
shelves, bins, drawers. Hi-Lo on
shelving above or below sight-lines.
Wire•Rac™ on wire shelving.
Magnetic Cardholders for instant
adhesion on metal. SuperScan™ for
scanable display on pallet racks.
Open•Edge™ for easy label
insertion on industrial shelving.
Write-On magnetic tags for
use with wet-erase markers. These
quality products assure you easy-read
identity with long-life durability. All
paper inserts are now laser ink-jet
compatible. Call for our
catalog
and nearest dealer.AIGNERI N D E X
Hol•Dex
Hi-Lo
Wire•Rac
MagneticCardholders
Open•Edge
Write-On
SuperScan
FREESamples!
Industrial fan delivers energy savingsThe durable and adaptable 8- to 24-foot diameter PowerfoilX industrial fan gener-ates maximum airflow. Engineered and machined from materials that promote year-round energy savings, the fan includes the supplier’s NitroSeal Drive custom gearbox. It is backed by a 10-year warranty with factory installation. Big Ass Fans, 877-244-3267, www.bigassfans.com. Booth 408.
New version of WMS features visualization Version 2.3 of Savanna.NET warehouse management software has been launched. New features include real-time 3D visu-alization of the warehouse, a dashboard for tracking key operations statistics, streamlined user rights management, and improvements to the order picking module for integrating third-party picking solutions. The Web-based system’s visual-ization functionality has been developed with gaming software and allows a view
of the facility from any angle. Individual items/SKUs can be identified and filtered, as can warehouse zones. Westfalia Technologies, 800-673-2522, www.WestfaliaUSA.com. Booth 3926.
Electric counterbalanced sit-down lift trucks
Eight models of the RX60 series of 80-volt electric counterbalanced sit-down lift trucks are offered. Capacities range from 5,000 to 10,000 pounds. Enhancements include an improved rail that strength-ens the mast and limits deflection, travel speeds of 12 miles per hour, and lift speeds of 100 feet per minute. The vehicles include a heavy-duty cast ductile iron steering axle, major electrical compo-nent placement inside the counterweight, and thermal protectors. Linde Material Handling-North America, 843-875-8319, www.lmh-na.com. Booth 641.
Handheld features open platform softwareThe Omnii modular mobile com-puting platform allows the sup-plier, its resellers and developer partners to co-create adaptable solutions through an open, online community. By being almost completely re-configurable in the field, devices built on the platform can be adapted for new technologies or be re-purposed as needs change. The XT10 device uses this plat-form and is IP65 rated. Features include a 6.5 foot drop rating, Texas Instruments OMAP3 processor, and extended battery life. Psion, 800-322-3437, www.psion.com. Booth 1423.
Handle longer loads with single-beam gantry craneA new line of single-beam, rubber-tired gantry cranes—the SB Series—is offered in 15-, 30- and 70-ton models. The cranes are ideal for handling longer loads and tandem picks, replacing a single 100-ton gantry with spreader bar. The weight of the load located directly below the frame. Shuttlelift, 920-743-8650, www.shuttlelift.com. Booth 1176.
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30 F e b r u a r y 2 0 1 1 / Modern Materials Handling mmh.com mmh.com M o d e r n M a t e r i a l s H a n d l i n g / O c t o b e r 2 0 0 9 27
APPLICATION REPORTS STORAGE/STAGING
Aircraft manufacturer saves space and time
When a military aircraft manufacturer installed new dividers to work with its vertical lifts, the upgrade had significant secondary benefits.
Not only did the new dividers cost less than half their metal counterparts, they weighed nearly half as much, too—allowing the manufacturer to store more product in its system.
The divider system was provided for eight units with 744 trays. The system consists of more than 60 different divider configurations, 19 of which were customized to meet the aircraft manufacturer’s parts handling needs. The newer, lighter equipment has saved the manufac-turer time, space and money since it was installed—in record time.
“The ease of installation far exceeded the customer’s expectation,” says a member of the installation team. “We were comfortably able to assemble all 744 divider kits with a four-person team in only two weeks. We thought it would take four.”
The consultation process included plenty of question and answer sessions, followed by repeated revisions of
the conceptual design. System designers built in addi-tional flexibility for future expansion. The end result saved 19% of the available space and more than half the cost and weight.
Flexcon908-871-7000www.flexcontainer.com
The system consists of more than 60 different divider
configurations.
Your work can’t wait. With Pro-Line’s “In Stock” Program, youcan get the exact modular workbench your application demandsin 5 days or less - with your choice of work surface, color, andmany accessories and options.• For decades, Pro-Line workbenches have been synonymous
with quality, functionality and unmatched ergonomic design.• Choose from the manual height adjust Ergo-Line, Millennium
II electric heightadjusting workbench,the popular ModelHD, Dimension NextModular Work-stations, and more. • Configure your
workstation with theexact accessoriesyou need.
Get the bench you need and get it fast.
www.industrialworkbenches.com
1proline.com(800) 739-9067
Pro-Line is a division of the R.W. Hatfield Co., Inc.
MMH091002_storage_ID.indd 27 10/12/2009 11:52:10 AM
Rider mezzanine lifts are
designed to move large
loads, and their operator
between floors or up
to mezzanines.
These lifts will travel
from 8 feet to 18 feet
and have platform sizes
ranging from 6Õ x 8Õ
up to 8Õ x 12Õ.
1-800-843-3625
www.advancel i f ts .com
RIDER
MEZZANINE
LIFTS
SHOW PREVIEW
load transfer station handles 2 loads per minuteA fully automatic load transfer station transfers up to two full loads per minute. Using a pallet stacker, pallet dispenser, input conveyor and an output conveyor, the station receives loads from a convey-or, transfers the load from one load base to another, stacks the pallet and auto-matically discharges the transferred load onto a conveyor. Transferred loads can then be stored in a high rise automated storage and retrieval system, picked up downstream by a lift truck, or travel to another operation. Columbia Machine, 800-628-4065, www.loadtransfer.net. Booth 972.
standard and custom containers A comprehensive line of plastic contain-ers, bulk boxes, carousel containers, and vertical lift dividers are offered in more than 3,000 standard sizes and any cus-tom size. Highlighted are a new line of insulated shippers, vertical lift dividers and custom case samples. Custom units are created to meet unique specifications and requirements. Flexcon Container, 908-871-7000, www.flexcontainer.com. Booth 1726.
Warehouse management and control systemA turnkey solution for warehouse con-trol and automation, supply chain labor, and warehouse information manage-ment is offered through a partnership between the supplier and Softeon. The system improves order picking and inven-tory management, while reducing labor through automated pick, pack and ship technologies. The system is ideal for each picking and mixed SKU item/case/pallet picking and shipping. numina group, 630-343-2604, www.numinagroup.com. Booth 4234.
steel lockers Valor lockers are constructed of prime, high-grade steel and feature a 14-gauge door, 16-gauge sides, top and bottom, and a 18-gauge back. An electrical cutout in the rear top corner offers access to an electrical feed for charging laptops, cell phones and other devices. To keep gar-ments cool and dry, the locker features maximum ventilation openings. lyon Workspace, 800-323-0082, www.lyon-workspace.com. Booth 659.
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mmh.com Modern Materials Handling / F e b r u a r y 2 0 1 1 31
increase conveyor speed with replacement spoolsFor quick replacement of standard line-shaft conveyor spools, the split-speedup-spool does not require disassembly of the conveyor to replace spools and spac-er tubes. The spools increase conveyor speeds by up to 44% while reducing noise. Capable of fitting both 1-inch and 25-millimeter line-shafts, the spools fea-ture alignment notches on one side for fast installation by feel behind frames or guards, and in lit or dark areas. Colored bright green for safety, the spools visu-ally indicate which conveyor zones are moving faster. dura-Belt, 800-770-2358, www.durabelt.com. Booth 352.
sort high densities at high speedsOffered with multiple tray configura-tions to allow for maximum throughput capacity and gentle product handling, high speed unit sorters improve accuracy, productivity and efficiency. The simple and flexible sorters handle high densities at quiet decibels. They are ideal for sort-ing pharmaceuticals, books, multimedia, small packages, flats, shoes, jewelry, office supplies, e-commerce items, opti-cal products, apparel and accessories. To
Pick-to-light for kitting, picking processesIntended for error-proof use in parts pick-ing, kitting, assembly and sequencing, the Build2Light is a complete light-directed picking system. The system is engineered for production environments, with low cost of entry and scalability, making it ideal for pilot programs. All key hardware is included, enabling operator self-sufficiency, fast installation, and stand-alone function without the need to interface with larger host manufacturing applications. lightning Pick technologies, 262-250-2143, www.build2light.com, www.lightningpick.com. Booth 4250.
environmentally friendly suspension packaging Ideal for low-profile, small electronics, the Korrvu Hybrid packaging creates retention-type surface protection with a suspension-type hold. The system uses a proprietary retention frame and elastomeric film. When the side flaps of the corrugated frame are folded up, the attached film is loosened, creating an insertion pocket where the item is placed. When the flaps are folded down, the film stretches over the prod-uct to hold it securely in place. sealed air, 800-648-9093, www.sealedair.com. Booth 3919.
suit specific application needs, various induction methods and sorting destina-tion types may be specified. eurosort, 410-363-6345 www.eurosort.com. Booth 2619a.
new module for rFid-enabled load tracking systemThe new Orchestrator work queue and task management module has been added to the VisiblEdge RFID-enabled system that auto-mates data capture for location and identifica-tion of lift trucks and their loads. By leveraging automated load and location data capture capabilities, the module improves the forklift operator’s experience. It also integrates with a facility’s WMS or ERP to streamline the dis-tribution and execution of material movement work instructions. rush tracking systems, 913-227-0922, www.rushtrackingsystems.com. Booth 141.
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32 F e b r u a r y 2 0 1 1 / Modern Materials Handling mmh.com
live roller conveyor replacement beltsThe economically priced TF-100T live roller conveyor belt is offered. Capable of navigating small conveyor pulleys, the belt cuts replacement costs. If needed, the unit can be spliced directly into the exist-ing belt. Habasit america, 678-288-3600, www.habasitamerica.com. Booth 1044.
intelligent jib moves with operator Offered as an easier-to-move alterna-tive to the traditional workstation jib/chain hoist combo, the G-Jib includes the G-Force intelligent lifting device in conjunction with a workstation jib crane. The actuator of the lifting device stays in a fixed position near the vertical truss of the crane, eliminating the dead weight that comes with moving a hoist along the rail. The system travels with the motion of the operator and is offered in two capacities: 330 and 660 pounds. gorbel, 800-821-0086, www.gorbel.com. Booth 3623.
easily identify inventory with clear view storage binsFor inventory organization, clear-view ultra stack and hang bins are made of injection-molded polypropylene. Front, back and side grips provide easy handling, while a built-in, rear hanger suspends the bins from louvered panels or rails. Resistant to rust and corrosion,
Workstation includes on-board powerTo run a computer, printer and other devices simultaneously, the PC series mobile powered workstation incor-porates on-board power, along with ample shelf space for products and other items. When charged, the cordless battery offers integrated, seamless power for up to 12 hours of normal use. Six-inch swivel casters lock for stability once the portable station is positioned. Carts come in dimensions up to 24 x 48 x 37 inches with five differ-ent battery/inverter/charger packages. newcastle systems, 781-935-3450, www.newcastlesys.com. Booth 4768.
inventory management and control softwareFastPic5 inventory management and control software now provides a batch handling function to improve throughput and productivity. The software employs three methods: static batching creates batches ahead of time at the order entry department; dynamic batching builds the next batch for the operator to reduce workload; and operator-defined batching allows the picker to create the next batch from a list of pending orders. The system integrates with host software, pick and put-to-light technology and automated storage and retrieval systems to increase throughput up to 600% and accuracy rates up to 99.9%. FastPic, 207-854-8663, www.fastpicsystems.com. Booth 2919.
SHOW PREVIEW
MMH1102_ShowPreview2.indd 32 2/9/11 12:22 PM
Print, apply shipping label and packing slip For distribution and fulfill-ment centers, the TwinPrint system includes printers and printer applicators with two printheads that print both the shipping infor-mation and a confidential packing slip on a single label. Once applied to the carton, the packing slip is accessed by tearing a zipper strip. The informa-tion on the printed liner remains confidential and provides tamper-evident protection during shipping. By repurposing the label liner as the packing slip, the system eliminates a traditional packing slip and plastic envelope from the waste stream. FOX IV Technologies, 877-436-2434, www.foxiv.com. Booth 4103.
Customize WMS with applications from app storeOffered as an “app store” for the supplier’s warehouse man-agement system, the App Station is a collection of workflows that can be browsed and added to the WMS at any time. All apps are free and user-installed to add functionality without custom-coding. The system includes access to new supply chain software innovations, and the ability to pick and choose only the functionality needed for the WMS without affecting current customizations. HighJump Software, 800-328-3271, www.highjump.com. Booth 4572.
CLARK_ProMat11_MMHhlfvrtad_0311.indd 1 2/2/11 3:50 PM
VLM offers Web-based inventory managementIntended for discrete part storage and retrieval, the PowerColumn3 vertical lift module incorporates automated height sensing for slotting flexibility by tray height. Five tray widths, four depths, two tray-carrying capacities (1,000 and 2,000 pounds), and 11 configurations are includ-ed standard. Heights range from 10 to 50 feet, and custom models may be specified. The VLM incorporates intelligent inven-
tory management and control in a software as a service format, allowing the linkage of multiple machines in different locations together through Web-based software. SencorpWhite, 800-275-1442, www.sencorpwhite.com. Booth 4407.
Repair floor cracks with deflection deviceThe Joint-Saver can be used to repair loose, rocking, spalled joints and cracks in flooring that can damage materials handling equipment and cause injury and tipped loads. The cost-effective repair device is offered in three sizes to accommodate a range of floor thicknesses in ambient and cold temperature environ-ments. The units eliminate damaging deflection and permanent-ly restore smooth, positive load transfer at all joints and cracks. Surface Dynamics, 800-584-5553, www.someromatsongroup. Booth 1274.
the bins are waterproof. Dividers maximize flexibility and keep contents organized. Twenty different models are offered, in sizes ranging from 5 x 4.125 x 3 to 17.125 x 14.75 x 10.25 inches and capacities from 8 to 75 pounds. Quantum Storage Systems, 800-685-4665, www.quantumstorage.com. Booth 1922.
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Conveying Loading Palletizing Packaging Sortation/Distribution
Courier, express and parcels services
BEUMER sortation and distribution technology to reach your objectives quickly and smoothly.
Extreme cost-ef ciency combined with the highest sortation capacities for packages and parcels of all sizes – these are the demands of modern courier, express and parcels services. BEUMER sortation and distribution technology provides you with a complete high-performance system. Individually programmed to meet the required conditions, BEUMER sorters win over through their creative solutions for the safe, fast and gentle handling of packages and parcels of any shape or size. You can nd more information about the BEUMER company and its products on the Internet.
www.beumer.com
SV
1.U
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Visit us atProMAT Show21 - 24 March, 2011Booth #3203
U_AZ_98,4x266,7_KEP_S+V_USA_Promat.indd 1 20.01.11 08:5
SHOW PREVIEW
New products include tugger, heavy-duty workstation components, rollers
Three new product lines include the BST automated guided vehicle tugger, a 42-mm pipe-and-joint system for heavy-duty applications, and a roller conveyor system. The AGV drives under a stationary cart equipped with a BST hitch, extends a tow pin to engage the cart and moves it to a predetermined loca-tion. The pipe-and-joint system cre-ates heavy-duty structures without the need for excessive bracing and is ideal for assembly and finishing
operations where part size and weight require workstations with powered height adjustment capabilities, flow racks and carts. The Placon roller conveyors deliver stability and smooth flow from wide plastic wheels in a variety of sizes to accommo-date totes with soft bottoms or open cell designs. Creform, 800-839-8823, www.creform.com. Booth 4814.
Five models of laser guided vehicles For high volume consumer goods manufactur-ers, a laser guided vehicle line comes in five standard models: counter-balanced narrow, counter-balanced wide, single reach, double reach and very narrow aisle. These fourth-generation LGVs include AC drives and motors, advanced torque control, full Windows-based control system, one-piece frame construction, standard electrical components, and advanced remote support for controls system and components. The vehicles interface with block and floor storage, selective rack, drive-in rack and gravity flow rack. Elettric 80, 618-433-9290, www.elettric80.com. Booth 2031.
Charger for batteriesThe Legacy Titanium HF industrial battery charger uses advanced high frequency, insulated gated bipolar transistor charging technology. The charger delivers a high power fac-tor and high efficiency to reduce utility demand charges and AC consumption. The system constantly diagnoses a battery’s condition and adjusts the charge for full, accurate charging. It is ideal for tubular, flat plate and flooded lead acid batteries. Douglas Battery, 800-211-3684, www.douglasbattery.com. Booth 1121.
Show pickers tasks, picks with visual WMSTo streamline putaway, picking and packing, the version 8 of the EliteSeries warehouse management system includes a new visual logistics paradigm. The new module leverages visual communication for system-directed tasks that in a faster format that is more understandable by pickers to increase throughput and accuracy. The delivers instructions to workers directly on their RF gun or handheld computer and visually communicates the activities they can execute in an optimum time. Tecsys, 800-922-8649, www.tecsys.com. Booth 3872.
MMH1102_ShowPreview2.indd 34 2/9/11 12:22 PM
Think of evolution in fast forward. HAWKER’s new LifeSpeed™ 3000
charger can charge lift truck batteries to 100% from an 80% DoD
in just 2 to 3 hours, using a patented algorithm with discharge
pulses that prevent overheating.
LifeSpeed™:
• Works with little or no modification to your system
• Is a fraction of the weight and size of other fast chargers
• Is fully automatic and adjusts to the battery’s voltage
• Eliminates the need for truck battery changes so that
multi-shift operations are able to run on one battery
• Dramatically reduces space, energy, downtime, and costs
The Evolution of the Motive Power Charger: LifeSpeed™.
Leading Edge Power Solutions • HAWKER • P.O. Box 808, 9404 Ooltewah Industrial Dr. • Ooltewah, Tennessee 37363 USA
Ph. (423) 238-5700 • (877) 7HAWKER • Fax (423) 238-6060 • www.hawkerpowersource.com
SPEED MEANS MONEY.Ask your HAWKER Representative to perform a Harness the Power
Assessment™ to see if LifeSpeed™ is right for your application.
Visit HAWKER
at Booth #1827
at the 2011
ProMat Show.
You also get Battery Boss®, a compact real-time diagnostic system that
attaches to the battery and provides detailed performance reports.
MMH0211_Ads.indd 35 2/3/11 10:19 AM
A new generation of spiral conveyors
deniconda® – an innovative spiral conveyor that
cleverly compensates for height differences.
– lightweight, but resilient
– modular belt with rolling support on the inside
radius for low power consumption
– very reliable and low on maintenance
– modular design
For more information, just send a mail to
®deniconda
denipro…Unternehmen für fördertechnische Teile und Komponentenbau
General importer
WRH Marketing Americas, Inc.
3150 Brunswick Pike, Suite 220
Lawrenceville, NJ 08648
Visit us
ProMAT 2011
Booth
#3531
inserat_denipro_3_3_8x10in_260111.indd 1 26.01.11 15:33
SHOW PREVIEW
Single mobile computer performs multiple tasksDelivering faster real-time data capture through its PXA 320 806 MHz processor that runs either Windows Mobile 6.5 or Windows CE 6.0, the Tecton rugged hand-held computer performs multiple tasks. Multi-range scanning capabilities enable bar code reads from 4 inches to 40 feet. Features include an easy-grip handle with two-finger trigger, molded rubber grip, wrist strap, scan vibration signal to verify successful scans, and multiple built-in data-
entry options, including a 3.5-inch touchscreen with stylus, 55 or 32 key backlit keypads, and voice technology. LXE, 800-664-4593, www.lxe.com. Booth 4268.
System helps retailers plan assortments based on customer buying habitsTo help retailers predict consumer buying habits, the customer-preference planning product monitors purchases and selection drivers to help with merchandise and assortment planning. The system improves return on investment by matching assortment strategy with customer preferences and financial goals with tailoring to match local demographics. The system is offered as part of the supplier’s planning and forecasting supply chain process platform suite, which facilitates interactions among mul-tiple software applications. Manhattan Associates, 678-597-7274, www.manh.com. Booth 3668.
ERP suite focused on cost reduction, process improvementThe new release of Epicor 9.05 enterprise resource planning suite includes capabilities focused on cost reduction, process improvement and customer responsiveness. Available in 50 countries, the release introduces lean performance metrics, enhanced quality assurance, and a focus on both inbound enter-prise asset management and outbound aftermarket mobile service management. Expanded functionality for measuring key performance indicators across all operations includes advanced financial reporting capabilities, an embedded configurable asset management engine, and advanced allocations module. Epicor Software, 800-999-6995, www.epicor.com. Booth 3571.
Zoned accumulation conveyorFor handling of medium- to heavy-duty loads, a zoned accumulation conveyor features roll-to-roll chain driven live rollers. Zone lengths can be configured to coincide with the prod-uct lengths, with the entire conveyor length driven by a single power unit. Clutch assemblies are mounted on the side frame of the conveyor, with the top of each roller as low as 6 inches off the floor, for a low profile—ideal for heavy loads and pallet conveying. Rollers are offered in diameters of 1.9, 2.5 and 3.5 inches and widths up to 60 inches, with typical loads weighing up to 6,000 pounds. TKF, 513-241-5910, www.tkf.com. Booth 2249.
MMH1102_ShowPreview2.indd 36 2/9/11 12:22 PM
For More Information, Call:
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38 F E B R U A R Y 2 0 1 1 / MODERN MATERIALS HANDLING mmh.com
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SHOW PREVIEW
Rugged mobile computer Offered in handheld and pistol grip ver-sions, the Falcon X3 provides real-time data capture and communication for accurate inventories and enhanced pro-ductivity. It may be equipped with either laser scanner or 2D imager with a read feedback function to ensure accuracy.
New swivel technology integrated into heavy-duty, forged steel castersOutperforming conventional CNC-machined ball race-ways, kingpinless and unit-load bearing swivel constructions, a new swivel technol-ogy is offered on the supplier’s heavy-duty forged steel cast-ers. Load capacities range from 600 to 23,000 pounds. The new HPI configura-tion improves the bearing’s element of contact to double the number of contact points. Equipped with raceways that are 45% harder than conventional models, and a smooth, 16 micro inch finish, the casters swivel more easily under heavy loads. Hamilton Caster, 800-733-7655, www.hamiltoncaster.com. Booth 2662.
Double handling capacity with spiral conveyorTo handle double the capacity of the supplier’s standard products, a new high-capacity spi-ral conveyor has been introduced. The conveyors ship in one piece to reduce time and cost of instal-lation. Maximum load capacity is 75 pounds per linear foot at speeds up to 200 feet per minute, meaning the total weight capacity in the spiral at any one time is 3,600 pounds. For savings in ener-gy, as well as controls and system integra-tion, only one drive motor is required. The spirals can also be configured with a high-speed induction conveyor to allow loads to enter from several different elevations. Ryson International, 757-898-1530, www.ryson.com. Booth 1523.
To integrate seamlessly with WMS and ERP management systems, the mobile computer is packaged with Windows CE or Windows Mobile 6.5. For peak com-munication coverage, the device includes a Summit Wi-Fi 802.11 a/b/g radio with unique diversity antenna. Other fea-tures include numeric and alphanumeric
keyboards located at the operator’s fingertips, a universal numeric phone key layout, crisp display and backlit key-board. The computer resists numerous drops from 6 feet. Datalogic Mobile, 800-929-7899, www.mobile.datalogic.com. Booth 4108.
MMH1102_ShowPreview2.indd 38 2/9/11 12:22 PM
mmh.com
Innovative Automated
Solutions
www.interlakemecalux.com1-(877)-MECALUX
Electric trucks lift 4,000 poundsThe E30-40XN series of electric lift trucks is available in 3,000 and 4,000 capaci-ties. The vehicles include newly designed operator compartments, increased floor space, auto deceleration system to reduce operator fatigue for materials handling applications. By utilizing AC motors and transistor controller tech-nology for the traction and hydraulic systems, cost of maintenance is reduced. The thermal management system con-tinuously monitors the controller and motor temperature and, upon identifying irregularity, the system protects the com-ponent by automatically adjusting truck performance. Hyster, 800-497-8371, www.hyster.com. Booth 1503.
Patented double leg ratchet pallet The ProStack double leg ratchet plastic pallet features solid construction with telescoping double legs to extend its life in tough handling situations. The pallet’s stringer is ori-ented to prevent pallet jack wheels from stopping on top of it, eliminating dam-age when misplaced pallet jacks are over-pumped, breaking the top deck. Other features include a ratchet locking system up to four-times stronger than welded or snap construction, edge-rackability to 2,200 pounds, and FM-approved fire retar-dance. For a smooth finish, enhanced stiff-ness and better resistance to impacts, the pallets are formed in a gas-assist molding process. Polymer Solutions International, 877-444-7225, www.prostackpallets.com. Booth 205.
Pivoting shelves enhance capacity of mobile cartThe Tip-Up shelf cart includes integrated shelves that move and maneuver effort-lessly. The carts increase storage and make part arranging easier. When the counterbalanced shelves are lifted, pivoting is offset with added weight. The shelves automatically lock in place, giving the operator full access to the entire span without exertion. Shelves are loaded from bottom to top, with each shelf above tipped up as needed. Topper Industrial, 262-886-6931, www.topper-industrial.com. Booth 4564.
Modular, tear-drop connection storage rack A universally compatible, tear-drop pallet rack system includes four column profiles and nine popular beam sizes for maxi-mum flexibility in creating and expanding pallet rack storage systems. Fully welded uprights are roll formed in either four or six bend column profiles with 2-inch vertical adjustability, and include weld-on baseplates, a center reinforcing column rib and heavier bracing for strength, rigidity and impact resistance. For posi-tive beam-to-column engagement, all beams feature a patented, rugged auto-matic spring-lock pin mechanism. The racks are ideal for selective and high-den-sity storage. Ridg-U-Rak, 866-479-7225 www.ridgurak.com Booth 1241.
Easily replace damaged panels on high-speed doorFeaturing easily replaceable, exchange-able panels made of vinyl, mesh, or clear PVC, G-2 high-speed roll-up doors can be repaired or modi-fied to accommodate seasonal changes without down time or destruction to the door. Rated for wind loads of 45 miles per hour (10 x 12-foot unit), the doors automatically reset after impact or blow out. Fiberglass extrusions slide securely in custom extruded aluminum side beams for manual and motorized opera-tions including chain hoist, or 12-, 28- or 36-inches per second. Goff’s Enterprises, 800-234-0337, www.goffscurtainwalls.com. Booth 312.
Dynamic sensor controls warehouse lighting Unlike conven-tional sensors that switch rack and warehouse lighting fixtures on and off, the InteLite dynam-ic sensor provides a safe transient mode that reduces typical aisle or stor-age area lighting expenses by 90%. Intelligent controls activate lighting based on two types of motion: transient, which illuminates aisle zones with safe, low-level lighting for personnel passing through, and task, with individual fixtures illuminated at a maximum level when sustained activity is detected. Orion Energy Systems, 800-660-9340, www.oesx.com. Booth 1916.
MMH1102_ShowPreview2.indd 39 2/9/11 12:22 PM
AutomatedVertical
Storage SystemsIt All Adds Up
To VALUE
Lauyans & Company, Inc.1-866-LAUYANS (528-9267)
USA Manufactured
Small parts are expensive. Traditionalshelving eats up valuable ß oor space
and exposes parts. WhatÕs more, parts can be tough to Þ nd and reach; keeping
accurate inventories a challenge.
The Lauyans Small Parts StorageSystem (SPSS) is a USA manufactured solution offering high density storage
utilizing vertical space for greater footprint capacity, worker safety,
security, labor savings and the most competitive pricing available.
Before you decide to buy anyAutomated Storage System, go online
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It All Adds Up To VALUEIt All Adds Up To VALUE
SHOW PREVIEW
Truck series lifts up to 19,000 poundsOffered with a choice of engines, the Veracitor VX truck series features low fuel consumption, minimal noise, and reduced maintenance and operating costs. Both cushion and pneumatic tire classes are included. Capable of lifting capacities from 3,000 to 19,000 pounds, the trucks employ a maintenance-free, built-in stability system. The rugged powertrain incorporates computer-controlled engine and transmission, sturdy clutch packs, and strong gears and shafts. All transmis-sions have smooth electronic inching to cut maintenance costs by eliminating periodic adjustments. Yale Materials Handling, 800-233-9253, www.yale.com. Booth 1003.
Compact scissor lift has 2,000-pound capacityThe DXL series compact scissor lifts feature a smaller foot-print than stan-dard lifts while offering 2,000 pounds of lifting capacity. The lifts are ideal for work posi-tioning, assembly, repair and inspection applications in factories, warehouses and repair shops. A double scissor mechanism allows for a low, 6-inch collapsed height while providing a 42-inch raised height. To operate the 1/3 horsepower motor, a foot switch is included. The unit comes equipped with a standard 18 x 30 inch platform. Other platforms, including oversized tops, may be specified. Presto Lifts, 800-343-9322, www.prestolifts.com. Booth 1831.
Modular vertical lifts debutTwo new modular verti-cal lifts have debuted. The Series D direct hydraulic lift for medium loads includes limited moving parts for easy maintenance. It is ideal for in-plant mezzanine, balcony and self-storage applications. It features carriage sizes up to 6 x 6 feet, handles payloads up to 3,000 pounds, and moves loads up to 15 feet high at a stan-dard speed of 17 feet per minute. The Series B modular lift moves boxes, cartons, barrels, loose parts and other portable loads to and from mezzanines and basements, or between two floors. The lift moves loads up to 500 pounds to heights up to 20 feet at a speed of 40 feet per minute. Pflow Industries, 414-352-9000, www.pflow.com. Booth 1216.
Wood block rental pallets hold 2,800 poundsUsed by manufacturers and retailers throughout the U.S., Canada and Mexico, a wood block rental pallet measures 48
x 40 inches. Constructed with 26 boards and 138 fasteners per unit, the edge-rackable pallets hold loads weighing up to 2,800 pounds. Features include 87% top deck coverage, non-slip traction in refrig-erated areas, and no deflection in over-head racks. The pallets are made from No. 2 grade Douglas fir and Southern yellow pine lumber that is sustainably forested. To control infestation, mold and moisture the pallets are kiln-dried; they are not treated with chemicals or hazardous mate-rials. PECO Pallet, 877-227-7326, www.pecopallet.com. Booth 2270.
Lift up to 50 tons with wire rope hoistA line of wire rope hoists comes in capacities from 25 to 50 tons. The Yale Global Max HC double-girder style hoist features an external motor to optimize
cooling and maximize accessibility. The remote mounting of the motor and brake prevents heat transfer in either direction and allows for easy maintenance. The hoist includes a sealed, fully enclosed, pressure tested gearbox with all gears submerged in oil for protection. To elimi-nate slack rope during operation, a fully enclosed free loop guide is incorporated. Columbus McKinnon, 800-888-0985, www.cmworks.com. Booth 1838.
MMH1102_ShowPreview2.indd 40 2/9/11 1:07 PM
mmh.com Modern Materials Handling / F e b r u a r y 2 0 1 1 41
Building workstations with the Creform System of pipes and joints can significantly reduce the amount of floor space needed. Build it for one person, a team of six or sixty, there’s no need to use more space than necessary to complete the task. Over 700 Creform components help you expand within existing floor space.
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Voice software supports central application management Version 4.0 of Voxware 3 soft-ware for voice picking has been released, featuring an expansion of its voice manage-ment module. The upgrades enable the deployment and management of voice pick-ing applications from a central data center across multiple warehouses of differing sizes and layouts. Other features include enhancements to order picking, replenish-ment, and putaway applications. To enhance open hardware support, the software also includes embedded, enterprise-grade AirWatch mobile device management technology, allowing for secure monitor-ing, management and support of all mobile devices in a fleet. Voxware, 609-514-4100, www.voxware.com. Booth 3672.
automate dimensioning, weighing for shippingTo eliminate freight-carrier charge-backs, the CubiScan 150 automates the dimensioning and weighing of parcels in manifesting/shipping applications. It is user-installable, user-serviceable, and portable for relocation throughout a warehouse. The device is certified to a variety of legal-for-trade standards. It works in conjunction with the supplier’s Qbit data-interface software, allowing it to interact with any WMS. Quantronix, 800-488-2823, www.cubiscan.com. Booth 3912.
decentralized control for materials handlingMovifit intelligent decentralized control combines with drive application and com-munication technologies for automotive, food and beverage, logistics and other materials handling applications. Offered in standard IP65 and hygienic washdown IP69K-rated construction, the system is flexible and scalable in a range of envi-ronments. Preconfigured control routines for horizontal and vertical conveyor appli-cations provide ready-to-use functions that simplify programming and start-up. seW-eurodrive, 864-661-1120, www.seweurodrive.com. Booth 1555.
See us at ProMat booth 4814
MMH1102_ShowPreview2.indd 41 2/9/11 3:36 PM
42 F e b r u a r y 2 0 1 1 / Modern Materials Handling mmh.com
a warehouse control
system and new
technology are the
heroes at simon &
schuster’s new Jersey
distribution center.
By Bob trebilcock, Executive Editor
MMH1102_SysRptSimonSchuster3.indd 42 2/9/11 1:09 PM
GraphicCaption Feature
mmh.com Modern Materials HandlinG / F e b r u a r y 2 0 1 1 43
modern system report
Simon & Schuster: A twice-told tale
PH
OTO
GR
AP
HY
BY
JEFF FU
SCO
very distribution center has a story to tell, especially one that’s gone through a signifi-cant system upgrade. Some
have happy endings, some are thrill-ers, and some are mysteries (What were they thinking?).
The story of Simon & Schuster’s 600,000-square-foot book distribu-tion center in Riverside, N.J., is a little like a historical novel, one that unfolds carefully over time with a number of chapters through the years. Today, the facility ships more than 135 million units a year, relying on a mix of materi-als handling equipment and technolo-gies that have been optimized around flexibility and efficiency. That wasn’t always the case, but it won’t ruin the story if we jump ahead to the end first.
Most recently, Simon & Schuster implemented a new warehouse con-trol system (WCS; AL Systems, www.alsystems.com) to synchronize manual processes, like full pallet and pick-to-pallet picking operations, with a voice-driven piece picking operation that also uses conveyor and a sliding shoe sortation system. The WCS also updates the warehouse management system (WMS) in real time, ensuring that all of the components of an order arrive at the dock at the right time to get best-selling titles to retail and wholesale booksellers.
The improvements also allowed Simon & Schuster to consolidate order fulfillment operations that had been spread across 1.2 million square feet in two facilities into the one 600,000-square-foot space in
Riverside. “We’re shipping 50 mil-lion more books and audio CDs than we did last year from this one facility with fewer people than we had in the two facilities,” says Dave Schaeffer, vice president of distribution and ful-
E
“We’re shipping 50 million more books and audio Cds than we did last year from this one facility with fewer people than we had in the two facilities.”
—Dave Schaeffer, vice president of distribution
and fulfillment
MMH1102_SysRptSimonSchuster3.indd 43 2/9/11 1:10 PM
44 M o n t h 2 0 0 5 / Modern Materials Handling mmh.com
modern system report
fillment. “All told, we increased our throughput by 50% while adding just 20% more manhours.” But, that’s only part of the story.
Setting the stage for improvements Simon & Schuster, the publishing divi-sion of CBS Corp. and one of the best
known names in consumer publish-ing, was founded in 1924 by Richard L. Simon and M. Lincoln Schuster. The publisher releases books under the Simon & Schuster name as well as through such well-known imprints as Pocket Books, Scribner, Free Press, Atria, Touchstone, Gallery Books, Howard Books, Threshold Editions, Atheneum Books for Young Readers, Little Simon and Simon Spotlight, and audio under the Simon & Schuster Audio banner. Publishing nearly 2,000 titles a year that are distributed in more than 100 countries, the list of authors includes Stephen King, Jodi Picoult, Glenn Beck, Vince Flynn, David McCullough, Mary Higgins Clark and Bob Woodward. Simon & Schuster also provides distribution services to inde-pendent publishers.
Today, about 70% of Simon & Schuster’s annual volume is shipped from Riverside; the rest is shipped directly to accounts from the printer. The facility supports several channels includ-ing large retail customers like Borders and Barnes & Noble; online retailers like Amazon.com; wholesale distributors; independent bookstores; price clubs and mass merchants; as well as a limited direct-to-consumer business.
That wasn’t always the case. The Riverside facility was originally built in the 1950s by Macmillan Publishing Co., which had a significant textbook and reference business. When Simon & Schuster purchased Macmillan in 1995, it already had its own
600,000-square-foot distribution cen-ter in Bristol, Pa.
For years, says Schaeffer, the pub-lisher operated both facilities. That’s because the two facilities had distinct layouts to support unique businesses. Simon & Schuster’s facility in Bristol was built for the consumer market: The facility carried large volumes of a relatively smaller list of titles with a short life span—the latest bestsellers were shipped to Bristol from the printer and then quickly turned around to fill demand at stores.
The Riverside facility in its original configuration was just the opposite: It carried small volumes of a large number of SKUs that might remain in reserve storage for years. That’s because library reference books might have a shelf life of many years. “When I started work-ing there, we had one title that we had only shipped twice in two years,” says Schaeffer.
Originally, Simon & Schuster wanted to combine the two facilities into Riverside, which had a total of 48,000 pallet positions. The problem: The facilities used different pallet sizes, which meant the inventory in Bristol wouldn’t fit in the racks in Riverside. “We were constantly chasing our tail capacity-wise because our volumes continued to grow and the Riverside facility wasn’t as space efficient as it needed to be,” says Schaeffer.
Starting in 2000, however, Simon & Schuster began to write a new dis-tribution chapter through a step-by-step series of improvements. Each incremental improvement brought new capabilities and capacities to Riverside and laid the foundation for a new order fulfillment strategy and consolidation of the two facilities.
narrow aisle racking and lift trucks make the most of simon & schuster’s storage space.
MMH1102_SysRptSimonSchuster3.indd 44 2/9/11 1:10 PM
Writing a new chapterThe first of those steps involved gaining capacity. In 2000, the traditional pallet racks in Riverside were converted to a very narrow aisle (VNA) storage sys-tem and VNA lift trucks were added to the fleet. That change increased the case storage capacity of the building by about 45%, says Schaeffer.
The next year, Schaeffer outsourced returns processing to a third-party logis-tics provider, freeing up another 25,000 square feet in Riverside. In all, those two projects freed up about 50% of the storage space.
Those space-saving initiatives were followed by three more fundamen-tal improvements. In 2004, Simon & Schuster consolidated operations from a Canadian warehouse into the New Jersey facility, increasing volume by 10%. To accommodate that volume plus internal growth, two more shifts were added.
Once the third shift was in place, Simon & Schuster took on a series of technology and equipment upgrades in the 50-year-old facility.
• In 2005, a homegrown, legacy WMS was replaced with a Tier 1 WMS package.
• In 2007, the existing conveyor and shipping sorter were upgraded
to include a high-speed, sliding shoe sorter. The combination doubled the carton processing speed from less than 60 cartons per minute to 120 cartons per minute.
• That same year, the staging and shipping area was reconfigured and upgraded with the addition of four stretchwrappers. The palletizing area was tripled in size from having room to build 120 pallets to having room to build 384 pallets. And, additional space was created to stage about 1,000 pallets for outbound delivery. “We only have 11 dock doors, so we need to be able to stage pallets, especially on peak days,” Schaeffer says.
Designing for flexibility Despite those changes, the facility was still constrained for space. For instance, there might be 25 trailers in the yard that still had to be unloaded. “Although we have 48,000 pallet locations, at any given time, we might have just 100 positions open,” says Schaeffer. “Since we release between 50 and 100 new titles a week, if we don’t ship today, we can’t receive tomorrow.”
In addition, the volume of business going through the facility is variable. “Since we don’t own our own stores, we have to respond to customer demand and
that changes according to how the titles are selling in the market,” says Schaeffer. “Our inbound order volume can vary by a magnitude of five times from a low busi-ness day to a peak business day.”
Being able to respond to sudden shifts in volume led to more changes with a goal of creating a system that is accurate, efficient and flexible, especially around piece picking.
Beginning in 2008, Simon & Schuster re-engineered the split case picking area, replacing a traditional serpentine system, where an associ-ate picked from pallet flow rack and worked his way through the pick zones, to a centralized split case picking area directed by voice and serviced by an automatic case erector and a conveyor and sliding shoe sorter similar to the shipping sorter.
To gain capacity, a mezzanine was added. That addition created room to consolidate the titles still shipped from Bristol. Finally, the project included a new warehouse control system. That measure provided more accountabil-ity and traceability as cartons traveled through the warehouse. “With the new system, we can record more information for quality control,” says Schaeffer. “In the old system, if an order was rejected, we had to check it against a lot of paper-work. In this system, we scan the ISBN number to check the order, which allows us to automate the QC processes.”
Bringing it all together Once all of the improvements were in place, Simon & Schuster was able to devise a new distribution strategy.
mmh.com Modern Materials Handling / M o n t h 2 0 0 5 45
modern system report
Cartons are delivered by conveyor to and from the order fulfillment and mezzanine areas in the facility.
MMH1102_SysRptSimonSchuster3.indd 45 2/9/11 1:10 PM
the WCS directs the movement of the cartons from one zone to another.” The system can also balance the work load by moving the cartons from a zone that is taxed to a zone with available capac-ity. “If the next zone is busy, the WCS will divert a carton to a zone that is idle to optimize the flow through the facil-ity,” Schaeffer says. “In the past, we were only as fast as the slowest line.”
As a result, where it once took up to 7 hours to move a carton through the line on a busy day, a carton can now be completely picked in 2.5 hours, even during a busy period.
While the old paper picking method was accurate, voice-directed picking has brought improvements in productiv-ity and accountability. The system, for instance, ties an associate to a pick. If there’s a problem with an order, “we can identify who handled the order and find out what happened,” says Schaeffer.
Simon & Schuster has also
implemented an employee incentive program that rewards employees for exceeding a certain number of picks per hour along with a standard for accuracy.
The most important key to success is that everyone working in the facil-ity, from the supervisors to human resources personnel and company exec-utives, learned how to do voice picking. “Everyone has become an advocate for voice from the top levels of our organi-zation on down,” says Schaeffer.
In addition to throughput and pro-ductivity improvements, consolidat-ing operations at Riverside has saved freight, since two orders going to the same store may have been shipped from two different facilities in the past, and improved the customer experience. “We constantly got complaints from customers because they received their order in two different cartons on two different days,” says Schaeffer. “Now, their order is delivered complete.”
Despite those improvements, the final chapter to the distribution story in Riverside has yet to be written. “Our next step will be to implement a labor management system across the ware-house,” says Schaeffer. “With engi-neered labor standards, we believe we can achieve greater productivity and greater pick rates.” M
modern system report
With order fulfillment processes con-solidated in Riverside, the Bristol facil-ity now serves two functions. For one, it provides reserve and over-flow stor-age for Riverside. If the inventory for a title falls below a 90-day supply in Riverside, pallets of inventory can be shipped from Bristol to replenish that title. In addition, the Bristol facility ships seasonal items, such as calendars.
The Riverside facility is now more in tune with an industry that is undergoing significant changes as e-books become an ever-larger percentage of the busi-ness. As such, Schaffer sees only mod-est growth in sales volume, but tremen-dous growth in the number of units and titles being sold. Attracting additional independent publishers as distribution clients is an ongoing strategic objective. Going forward, Simon & Schuster is shipping a smaller number of units per title, but more titles than in the past.
While full pallet and pick-to-pal-let carton picking operations are still directed by RF and bar code scanning, the combination of a new WCS, the automatic carton erector, conveyor and sortation equipment and voice recogni-tion technology has driven a new level of productivity and accountability in the piece picking area.
“Prior to putting in the carton erec-tor, we made all the cartons by hand in the pick zones,” says Schaeffer. “Now,
As part of the latest improvements, voice
recognition and a sophisticated warehouse
control system were added to improve picking processes.
46 F e b r u a r y 2 0 1 1 / Modern MAteriAls HAndling mmh.com
simon & schuster relies on extendable conveyors to receive floor-loaded trailers.
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In Simon & Schuster’s new materials handling system, a warehouse control and warehouse management system
(WMS) work together with bar code scanning and voice recognition tech-nologies to manage inventory and orders.
Receiving: Simon & Schuster gets close to 100% advance shipment notifica-tions (ASNs) from its printers. Inbound freight is scheduled by appointment and prioritized by criteria such as how well an item is selling. A shipment of a best-sell-ing title, for instance, may be given prior-ity over a replenishment title. About 80% of the inventory received (1) in Riverside arrives in full pallet quantities, although the facility receives some returns and some print-on-demand titles on pallets with mixed SKUs. Pallets are unloaded by lift truck. New titles that have never been stocked before are weighed and measured by the cubing and dimension-ing system to create a profile for stor-age in the WMS. Otherwise, a bar code label accompanying a pallet is scanned to determine a location on the dock where the pallet will be staged (2) for putaway.
Putaway: Once product is staged on the dock, it’s putaway into storage within 24 hours. Pallets are picked up in the staging area by the swing reach trucks that operate in the very narrow aisle storage areas (3) and are then directed by the WMS to a putaway location. The opera-tor scans a check digit to con-firm the putaway location and the pallet is now available in the system. In the current configuration, full cases are picked from lower levels in the storage area while the upper levels are used for reserve storage.
Replenishment: Pick waves are run daily in the WMS system, which also generates
replenishment orders throughout the warehouse based on the stock needs in split case (4) and full case picking (5) areas. To replenish the split case picking modules, for instance, the WMS directs an associate to pick the required cartons as if they were any other pick. The car-tons are labeled and inducted onto the conveyor system (6) that delivers them to the back side of the pick module for replenishment.
Picking: When it comes to picking, an order may be filled with a full pallet pick (3), split case picks (4), full case picks (5), or a combination of the three. When the WMS creates an order, it will generate tasks in three hierarchies. For instance, if a customer asks for 1,057 books, and there are 1,000 books on a pallet and 10 books to a carton, the
system will generate an order for one pallet, five cartons and seven individual picks. The system then synchronizes the picks so that all of the components of that order arrive at the shipping dock (7) at close to the same time by sup-plying the warehouse control system (WCS) with the carton records for that order. The WCS tracks the cartons and updates the WMS on the status of the order on a real-time basis.
Pallet picking: This is the most straight forward pick. The WMS directs an operator to a pick location (3). Once the operator confirms the pick by scan-ning a bar code, he is directed to a staging
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mmh.com Modern Materials Handling / F e b r u a r y 2 0 1 1 47
The book on distributionThe improvements allowed Simon & Schuster to synchronize manual processes
Simon & SchusterRiverside, N.J.size: 600,000 square feet
Products: Books, audio CDs
tHrougHPut: 11,500,000 units per month
stock keePing units (skus): 25,000
sHifts: 3 shifts/5 days per week
eMPloyees: 225 in operations
1
Receiving
7
Shipping
3
Reservestorage
4
4
Mezzanine:Split casepicking
5
Full casepicking
6
6
6
10
Sorter
12Sorter
11
Pallet build area
3
Reservestorage
9
Specialpicking
3
Reservestorage
2 Staging forreceiving
8 Staging forshipping
6 Conveyorsystem
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location (8) on the dock. Carton picking: The
Riverside facility stocks some titles that are perennial best-sellers. These are stocked in a special storage area (9) so they can be picked directly to the conveyor (6). For the remain-ing titles, picking instructions are delivered by the WMS to the operator on an RF termi-nal. Cartons are picked to a pallet (5), and an operator may be picking multiple orders for multiple customers. Once the pallet is full, the operator drops it off at a conveyor induction area, where the cartons are loaded onto the conveyor (6). They are conveyed to a quality control area, where the cartons are weighed and compared to a calculated expected weight. Following a bar code scan, each carton is sorted (10) to a pallet building area (11) near the dock. Once the pallet is built, it’s stretch-
wrapped and staged (8) on the dock. Split carton picking: To initiate
picking in the split carton area (4), car-tons are automatically erected and labeled with two bar codes that can be scanned on two sides. The empty carton is then sorted by the WCS to the right zone to
initiate picking. Picking is directed by the voice system. Once all of the items in the first zone have been picked, the WCS sends the carton by conveyor (6) to other zones until all the items for that carton have been picked. If the pick can’t be completed, the carton will cir-culate until a title has been replenished or it goes to a quality control area for completion. Once all the items for that carton have been successfully picked, it’s conveyed to the weighing and cub-ing station. A sorter (12) in between the picking areas and the shipping dock (8) diverts the last carton of every order to a station where the shipping papers are added. The carton is then conveyed to the pallet build area (11). There the pal-
let is built, stretch-wrapped and married to other components of the order on the dock (8).
Shipping: Once all of the compo-nents of an order have been assembled on the dock, they are loaded onto a truck for shipping (7). M
System suppliersWarehouse control system and voice recognition system: AL Systems, www.alsystems.comVoice recognition engine: Voxware, www.voxware.com Voice recognition devices: LXE, www.lxe.com Warehouse management system: Manhattan Associates, www.manh.com Conveyor system and sorter: Hytrol, www.hytrol.comPushback, carton flow, pallet flow, drive-in and bin rack systems: Frazier Industrial, www.frazier.com Narrow aisle (VNA) lift trucks: Landoll (Drexel), www.landoll.com/mhp/drexel/SL-50/Pallet handling lift trucks: Hyster, www.hyster.com Mobile and fixed bar code scanning devices: Psion, www.psion.com Printers: Zebra Technologies, www.zebra.com Weighing and dimensioning: Quantronix, www.cubiscan.com
modern system report
MMH1102_SysRptSimonSchuster3.indd 48 2/9/11 1:10 PM
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mmh.com MODERN MATERIALS HANDLING / F E B R U A R Y 2 0 1 1 51
MODERN special report
Productivity Achievement AWARDSModern’s annual Productivity Achievement Awards honor companies that have made out-standing strides in improving operations through materials handling and related information sys-tems. Modern’s editorial advisory board chose this year’s winners from a dozen candidates.
Companies were judged for their ability to deliver top-level customer service, respond rapidly to changing conditions, deliver orders that meet customer requirements, and improve operations. In addition, the innovation award celebrates a facility that employed a solution that defies convention.
InnovationCleveland Clinic
page 54
2011 WINNERS
Warehousing/DistributionOffice Depot
page 50
ManufacturingRubbermaid Commercial Products
page 52
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Office supply retailer consolidates four locations into one new demand-driven distribution center that’s powered by mobile robotics.
Office Depot:Flexible automation
hen Office Depot executives decided to consol-idate three distribution centers and a crossdock facility into one new state-of-the-art DC in
Newville, Pa., the office supplies retailer looked for an auto-mated materials handling solution that was efficient, flexible and able to deliver a competitive edge in the marketplace.
They found that edge in a goods-to-person picking solu-tion featuring two different mobile robots (Kiva Systems, www.kivasystems.com). One robot handles cases while a larger robot moves pallet loads in the facility that went live last year.
Office Depot believes the time has come for robotics in the DC, and it is taking the robotic system deep into its operations. Juan Guerrero, senior vice president of supply chain, explains, “Along with each picking, we are also doing case picking and full pallet movements with the robots.”
What’s more, Office Depot is using the robotic system to manage order fulfillment across all of its sales chan-nels, including store replenishment and bulk deliveries
to business customers. In all, 100,000 square feet of the 600,000-square-foot building are devoted to the system including the picking stations, which feature 300 robots and enough portable shelving space to manage three days of inventory. To minimize lift truck travel time, the mobile robotic system is augmented by a takeaway conveyor sys-tem and sliding shoe sorter. The robots have reduced the average travel by an associate from 7 miles per shift to less than half a mile; meanwhile the order cycle time has been reduced from 2 hours to 20 minutes.
“We believe that the future belongs to the brave,” says Brent Beabout, vice president of global network strategy and transportation. “We are in a commodity business and the supply chain is a differentiator. We plan to be on the front end of that.”
Starting from scratchOffice Depot is a leading supplier of office products and ser-vices, with more than $12 billion in revenue and 1,500 retail locations in 52 countries. The Newville DC was a result of a growth strategy that has been driven by acquisitions that brought new retail locations under the Office Depot umbrella and added warehouses and distribution centers. A few years ago, Office Depot had 33 buildings in its network, which
W
Read the complete article at:www.mmh.com/article/flexible_automation
Warehousing/Distribution Winner
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modern system report
came in two styles: crossdocking centers to replenish retail locations and DCs to service business customers and direct-to-consumer Internet and catalog orders.
Using the recession to review its network and optimize its systems, the company has reduced that number to 17, with a goal of reducing it to 12. To reach that number, Office Depot has closed and consolidated some facili-ties and upgraded the capabilities in remaining facilities. Newville, which serves 107 stores in the Northeast, was different. In that region, where the retailer operated four facilities with a total of 829,408 square feet, there was a unique opportunity to reduce the overall footprint of operations by build-ing a new facility.
Guerrero and Beabout wanted a sys-tem that could integrate with its home-grown warehouse management system to handle every line of business and sales channel where it operates. And, they wanted the flexibility to scale dur-ing seasonal periods or as the overall business managed by the system grows.
Finally, and most importantly, the system had to have the capabilities to manage Office Depot’s transition to a true, demand-driven distribution net-work. In the new pull model, every store will get a just-in-time delivery nearly every day of the week.
After looking at traditional pick and pack solutions, Guerrero and Beabout chose mobile robotics. The system uses a small robot to move mobile storage devices to and from associates at work-stations, and a larger vehicle designed to handle full pallets. Once picks have been completed, the robots deliver the units to a conveyor induction sta-tion, where the shipping containers are placed on a conveyor and sliding shoe sortation system and are sorted to a ship-ping lane.
Several factors led to this choice:Goods-to-person: The robots bring
product to the associate’s workstation, saving steps. In addition to productivity improvements, the system was very accu-rate, which would reduce picking errors.
Dynamic slotting: The robotic sys-tem monitors the movement of SKUs and slots the fastest moving items clos-est to the workstations. That leads to better use of the robots and minimizes the size of the fleet required.
Proven and reliable: Performance, recovery times from failure and risk management were robust enough for the Office Depot operation.
Flexible and scalable: What tipped the scales was productivity, the ability to co-mingle and pool inventory, flexibility to handle pieces, cartons and pallets, and the ease of adding to the
system in the future.While mobile robotics is providing
answers in Newville, that doesn’t mean Office Depot will adopt the technol-ogy everywhere. Beabout says, “We will assess each facility individually going forward. However, this was the right fit for this facility and our overall supply chain objectives.”
Bob Zelis, senior director (left) and Brent Beabout, vice president of global network strategy and transportation
System suppliersMobile robotic picking solution: Kiva Systems, 781-221-4640, www.kivasystems.com
Conveyor, dock conveyor and sliding shoe sorter: Dematic, 877-725-7500,
www.dematic.com
rack: UNARCO Material Handling, 800-862-7261, www.unarcorack.com
lift trucks: Crown, 419-629-2311, www.crown.com
Bar code scanning: Motorola, 800-722-6234, www.motorola.com
Print and apply: Pyramid Controls, 513-679-7400, www.pyramidcontrols.com
system design and integration: Office Depot, including a proprietary ware-house management system
PHOtOgRAPHy by AlAN WyCHeCK
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Rubbermaid:
By updating an aging manual storage system with automated cranes, Rubbermaid Commercial Products reduced costs and improved safety.
educe, reuse and recycle. Those are the three R’s of the sustainability movement. Going green may not have been one of the reasons Rubbermaid
Commercial Products chose to retrofit a manually oper-ated, high-bay warehouse with automated storage and retrieval cranes (Dematic, formerly HK Systems, www.dematic.com) at its 750,000-square-foot manufacturing plant and DC in Winchester, Va., but the three R’s are cer-tainly in play.
The company was able to reuse and recycle the existing rack infrastructure in a 20-year-old, high-density storage area containing 56,500 pallet positions in 200,000 square feet. Meanwhile, by replacing 10 aging manually driven stacker cranes with 28 automated cranes, Rubbermaid reduced the labor, created a safer work environment, and provided room for future growth.
Launched in November 2008, the project unfolded in four steps over 11 months
• choosing a solution and vendor,• designing the system and processes,• preparing for installation, and• finalizing installation.
It was a textbook example of solid design and project management coming together to deliver productivity gains with materials handling automation.
Time for renewalWinchester, Va., is the headquarters for Rubbermaid Commercial Products, a division of Newell Rubbermaid that manufactures a diverse line of products for business customers including waste management, facilities mainte-nance and materials handling products. The Winchester facility employs 800 associates, stocks about 7,000 SKUs and ships nearly 1,800 pallets a day in a 24/7 operation.
Two years ago, the division purchased Technical Concepts, a company that distributes complementary prod-ucts. This had an impact on the shipment profiles. “In the past, we primarily shipped large units such as trash cans that might have been stacked 20 to a pallet,” says John Elliott, senior distribution engineer. “Today, we might also ship a pal-let with 10,000 air fresheners.”
The 28-aisle, high-bay, high-density storage area was installed in 1989. Seventy-feet tall, it featured 10 manually operated stacker cranes. Six aisles were dedicated to com-ponents, materials and work-in-process to support manu-facturing while the other 22 aisles stored finished goods. After 20 years, the system had become expensive to operate and maintain. There were also safety concerns, so the time was right for a new system.
Manufacturer retrofits warehouse with AS/RS
R
Read the complete article at:www.mmh.com/article/rubbermaid_products
MODERN special report ManufacturingWinner
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modern system report
The right solutionIn the early stages of the evaluation process, Rubbermaid considered several proposals to update with another manually operated system. The proposal to automate with 28 aisle-dedicated cranes came later, after the team thought they were moving forward with a smaller-scale automated solution. Two things changed.
First was the introduction of a rotating fork materials handling device that can operate in a very narrow aisle and be retrofitted to a building with standard post-and-beam rack. The crane extracts a pallet from a storage location then rotates 90 degrees so the profile of the load is no wider than the overall profile of the storage and retrieval crane. The crane rotates 90 degrees again to put a pallet away in a stor-age location.
Second was that vendors were sharpening their pencils as they put their quotes together. On paper, the combination of automation, improved productivity and labor savings made the most sense.
Scoping the projectBetween November 2008 and April 2009, Rubbermaid assembled a project team that included opera-tions, maintenance and IT, and rep-resentatives from relevant vendors. IT representatives planned how different systems would communi-cate with each other and hand-off instructions. The team also decided to let its WMS continue determine putaway and retrieval locations and made necessary modifications and changes to the network, program-mable logic controls and Ethernet.
The next phase was to map all the process steps for the machines and cover every eventuality because without an operator, decisions and adjustments would now have to be controlled by automation. That required building logic for different sized products and different sized
rack locations, new controls for the conveyor system, and a validation process to prevent the wrong pallets from being inducted into the system.
A new system created an oppor-tunity to optimize the flow of materials, especially hot orders. In the past, if a hot order came into the system, a crane operator could retrieve a pallet and drop it off at an outbound station for pick up. Now, the system can change the priority of the picks. If there are already pallets staged on the out-bound conveyor, the system will bump up the priority of the pallets in the way so the crane can deposit the hot item for pickup.
Laying the foundationBy February 2009, the cranes were in production. Rubbermaid began installing wiring and data drops for the controls and machines and weld-ing together the floor rails. The rails were put to the side of the aisles so the old cranes could continue to operate since Rubbermaid expected to install the system piecemeal.
In April, the team visited the crane manufacturing plant to view a system test that successfully handled a load that matched Rubbermaid’s biggest load.
Implementing the systemIn May, the first aisle was shut down to install the first crane. It took three weeks, and required only minor modifica-tions and changes to the logic in the WMS to better match the physical locations to the prod-uct. Rubbermaid installed the remaining 27 cranes in about 16 weeks.
By October 2009, work was complete, the system was operational and productivity was improved. “We now have a system with reliable equip-ment that accommodates our needs today and will grow with us in the future,” says Elliott.
PHOTOGRAPHY BY JEFF HuTcHEns
John Elliott, seniordistribution engineer
System suppliers Systems integration, automated storage and retrieval cranes: Dematic, formerly HK systems, www.dematic.com
Warehouse management system: Manhattan Associates, www.manh.com
Drive in, pallet flow and case flow rack: Mecalux, www.interlakemecalux.com
Lift trucks: The Raymond corp., www.raymondcorp.com
Bar code scanning: Psion, www.psion.com
Conveyor and carton sortation: Intelligrated, www.intelligrated.com
Conveyor control system: Pyramid controls, www.pyramidcontrols.com
Stretch wrapping: Lantech, www.lantech.com
Extendable conveyors: stewart Glapat, www.adjustoveyor.com
Tuggers: Motrec, www.motrec.com
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sign outside the new 227,000-square-foot ser-vice center underneath the Cleveland Clinic’s parking garage says it all: Service to our patients
starts here.“That is our motto,” says Jeff Pepperworth, senior direc-
tor of materials management for the clinic, one of the nation’s premier medical facilities. “We are picking an aver-age of 70,000 units a day and many of those are critical to the treatment of a patient.”
To live up to that motto, the clinic went through a logistics version of health care reform: Pepperworth and his team vis-ited medical centers in Europe to design a system with capa-bilities similar to a just-in-time manufacturing environment and a direct-to-consumer e-fulfillment operation.
The result is a state-of-the-art distribution and order fulfillment center that went live in September 2008. The facility manages the delivery of product from five unique operating departments—everything from pharmaceuticals and surgical kits to meals and linens—to 14,000 employees in buildings across the 168-acre campus.
System components include:• Eighty RFID-enabled automatic guided vehicles (AGVs)
that identify and deliver more than 1,100 RFID-enabled carts,
• Light-directed picking from seven horizontal carousels with a total of 7,200 storage locations, a vertical carou-sel and carton-flow rack. The facility also has 850 pallet storage locations,
• Conveyor, lift trucks, reach trucks and man-aboard lift trucks for materials transportation,
• Information and automatic identification systems including enterprise resource planning (ERP) and ware-house management systems (WMS), and bar code and RFID technology, and
• Automatic battery charging to ensure that the AGVs are always in service.
Bringing materials handling up to speedFounded in 1921, today the Cleveland Clinic is the largest hospital system in Northeast Ohio. Its main campus has 26 health institutes; 1,300 beds; 3.3 million patient visits; and more than 50,000 hospital admissions a year.
Several years ago, the clinic launched an initiative to add 1.5 million square feet of clinical space, including new car-diac and urology facilities. With the anticipated increase
A premier medical center transformed a manual, paper-based warehouse into a state-of-the-art facility using automated technologies to deliver supplies to 14,000 locations.
A
Cleveland Clinic: A prescription for health care reform
Read the complete article at:www.mmh.com/article/cleveland_clinic
MODERN special report InnovationWinner
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in the volume of patients, the clinic needed to upgrade its systems.
The clinic set several goals:• Centralize materials management:
The new facility would bring together materials management for the linen department, patient food, waste man-agement, pharmaceuticals and surgi-cal supplies, general supplies and the retail operations under the management of one system under one roof – a roof located below ground and linked to the main hospital by a series of tunnels.
• Handle vertical and horizontal travel: The system had to manage deliv-eries to depots, or central queue areas, on the warehouse level (horizontal delivery) then track product to the right destination (vertical delivery).
• Respond quickly to demand: The clinic wanted to maintain several days of inventory for most products, which called for accurate inventory management and a system to quickly replenish supplies.
• Scale up or down according to patient levels: Initial plans called for picking 30,000 items a day. The system has been able to flex to meet the patient load that has grown as a result of bring-ing new facilities online.
• Implement with no shutdown:
Finally, the clinic needed to operate 24/7 while implementing new systems.
A new modelFrom the start, the team was working without a template: Pepperworth and his colleagues visited health care facili-ties in Europe and industry warehouses in the United States where automated materials handling systems were up and running. As a result, the clinic selected a variety of automated materials han-dling solutions to meet its goals.
At the heart of the system are 81 AGVs, each capable of moving up to 1,000 pounds. Product ready for delivery is stored on carts that are automatically picked up by one of the vehicles then transported through the tunnel system to a depot where carts are staged. Clinic delivery personnel pick up the carts then deliver them to the right destination.
The AGVs are enabled with an RFID reader that scans an RFID tag on the bottom of every cart. Through that scan, the AGV verifies that it is picking up the right cart for delivery; the RFID tag allows the system to track the AGVs’ location.
The clinic also installed opportunity
battery charging stations throughout the tunnel system and storage areas. In between moves, an AGV will go to the nearest station for a battery charge.
While AGVs are the most visible materials handling technology, they aren’t the only automation. Horizontal carousels are used in the primary materials management area to store and pick items with a relatively small cube. Horizontal carousels in the pharmacy area provide space-saving storage and added security. A vertical carousel stores documentation and literature.
Finally, to ensure accuracy, the sys-tem captures data throughout the deliv-ery process. In addition to an RFID scan by the AGV, associates scan a per-sonal identification bar code and a bar code on the cart when they pick up a cart at one of the staging depots. They are also required to scan a bar code to verify that they are at the right floor when they get off the elevator, and to capture an electronic signature to con-firm accurate delivery.
The system was operational from day one. And as the clinic continues its mis-sion of delivering quality care, the ware-house is supporting that mission. M
Jeff Pepperworth, senior director of materials management
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lincoln Electric, a Cleveland-based manufactur-er of arc welding machines and consumables,
was looking to better meet export shipping require-ments for its pallets, which were sometimes held up for inspection in Europe.
Lincoln was purchasing construction-grade pine and making export pallets in-house. “We were shipping nine different products and each had its own unique pallet design,” says Tom Soster, manu-facturing engineering manager for Lincoln Electric. In addition to maintaining an inventory of nine dif-ferent sizes that took up valuable space on an apron in the dock area, the pallets had to be bark free and made from heat-treated lumber to meet European regulations for pallets.
A presswood pallet (Litco International, www.litco.com/presswood-pallets.htm) offered a num-ber of benefits to Lincoln. The pallets are manu-factured using an environmentally responsible pro-cess that molds wood waste and wood byproducts under high heat and pressure, the pallets are ISPM 15 approved wood packaging and are guaranteed to be free of bugs, bark and mold. The pallets are also available in a half pallet size, measuring 24 inches x 40 inches—an ideal size for Lincoln’s welding machines.
“We received some samples of the pallet and by February 2009, we had changed over our first prod-uct,” says Soster. “On our first shipment, we learned that presswood pallets are common and welcomed in Europe. It was a very easy transition.”
The pallets also complement Lincoln Electric’s initiatives to stay lean and green: Since they are nestable and cradle-to-cradle certified, they free up valuable dock space previously dedicated to pallet storage and can be recycled at the end of their life.
Since then, Lincoln has changed eight additional pallets over to presswood pallets, delivering an esti-mated 5% savings on the cost of the pallets. And, Lincoln can order the pallets on an as-needed, just-in-time basis from a local distributor.
“The ability to order based on what we need means we can run a leaner operation,” says Soster. “And, since they nest, we can bring 50 pallets at a time into the product area instead of 25. That means fewer trips to move pallets.”
As an additional benefit, the presswood pallets are recyclable and earned a silver cradle-to-cradle certification from MBDC, an organization that assesses the sustainability of a product and the practices employed in making it.
“Like most responsible organizations, Lincoln Electric is concerned about sustainability,” says Soster. “Using a presswood pallet is not only meet-ing our shipping requirements, it’s making us a little more green.” M
LEAN ANd grEEN pALLEts
By noël P. Bodenburg, Executive Managing Editor
With a presswood pallet, Lincoln Electric is not only meeting European export requirements and streamlining its pallet inventory, it’s reaping sustainability benefits.
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By Lorie King Rogers, Associate Editor
Behind the backbone
Pallet rack is
a fundamental
component that can
maximize storage space
and have a positive impact on
organization, productivity and
throughput in your facility.
modern Equipment 101: Pallet rackA primer for warehouse/DC managers
Protective rails installed at the base of a rack system can safeguard against accidental impact and damage.
60 F e b r u a r y 2 0 1 1 / ModeRn MateRiaLs HandLing mmh.com
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mmh.com Modern Materials Handling / F e b r u a r y 2 0 1 1 61
If you’ve ever taken a placement exam, you might recall those analogy questions: “A is to B as C is to D”? Here’s one: Pallet rack is to a warehouse as a skel-eton is to a body. Both provide
structure and support to an overall entity. And, if part of either is broken, it’s very painful.
As end users expand their existing facili-ties or build new warehouses, new pallet rack is likely to be part of the conversation. What are most companies using today? “The shift in
rapid order fulfillment has impacted the types of systems that are in demand,” says Dave Olson, national sales and marketing manager for Ridg-U-Rak (www.ridgurak.com). “End users are still looking for selective rack, but there’s been more activity in recent years in flow systems and multi-level pick systems for rapid fulfillment.”
There are great reasons to have either tradi-tional rack or sophisticated rack for automated storage and retrieval systems in your facility. Both can have a significant impact on an operation’s ability to maximize inventory turns, minimize the amount of product on hand and turn it rapidly.
Efficiency continues to be a driving force in the materials handling industry, and the right racking solution in a warehouse can represent a company’s ability to remain competitive in the global marketplace. Proper planning can ensure complete and total efficiency in any warehouse,” says Linda Demke, CEO of Interlake Mecalux (www.interlakemecalux.com). “This permits the customer to establish a system that allows them to accurately understand all aspects of their inventory. Consequently, they are able to make quick and smart decisions and ultimately stay ahead of the competition.”
To determine which rack is right for your operation, let’s go back to basics.
Pallet rack systems are a key component of any warehouse or distribution center, and one of the most important tools in the materials
racking systems can be configured as stand-alone storage solutions, and they can also be specially designed to work with automated storage and retrieval systems.
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handling industry. Variations of these steel structures keep product orga-nized, provide storage, and maximize cube space from floor to ceiling. More importantly, they are central to get-ting product out the door. “A good rack system literally and figuratively sup-ports order picking,” says Kevin Curry, national account manager for Steel King (www.steelking.com).
Basic pallet rack consists of upright steel frames connected by horizontal steel beams. Pallets rest on the beams
between the upright frames. Two frames and the corresponding beams create a bay. The number of pallet posi-tions in a bay depends on the height of the frames and the spacing of the beams. High-rise storage systems can reach 100 feet, but 20 to 25 feet is a typical rack height.
The components of the upright frames—the steel posts and cross braces—can be bolted or welded together. Bolted construction is more prevalent in Europe, while welded frames are more
common in the United States.There are also two ways to connect
beams and frames: The components can be bolted to frames or interlock using a slotted connection system.
Rack components can be made of structural steel or roll-formed steel, with roll-formed being the most com-mon in the United States. Structural steel typically costs about 5% to 10% more than roll-formed. According to Olson, raw materials make up a signifi-cant part of the cost of rack. For that
modern Equipment 101: Pallet rackA primer for warehouse/DC managers
Company Web site telephone Headquarterssteel
structuralroll-
formedUprights Welded Bolted
Advance Storage Products
advancestorage.com 888-478-7422 Huntington Beach, Calif. x x
Boston Rack bostonrack.com 508-230-5755 North Easton, Mass. x x x
Bulldog Rack Co. bulldograck.com 866-285-5725 Weirton, W. Va. x x x
Elite Storage Solutions
basemfg.com 770-207-0002 Monroe, Ga. x x x
Engineered Products
engprod.com 864-234-4888 Greenville, S.C. x x x
Equipement Boni equipementboni.com 450-653-1299 Quebec, Canada x x x
Frazier Industrial frazier.com 800-614-4162 Long Valley, N.J. x x
Hannibal Material Handling
hannibalindustries.com 800-967-7009 Los Angeles, Calif. x x x
Interlake Mecalux interlakemecalux.com 877-632-2589 Melrose Park, Ill. x x x x
Konstant konstant.com 888-566-7826 Oakville, Ontario, Canada x x x x
LB International loadbank.com 800-458-9010 St. Cloud, Fla. x x x
Lyon Workspace Products
lyonworkspace.com 800-433-8488 Aurora, Ill. x x x
Nedcon USA nedcon.com 513-367-2656 Harrison, Ohio x x
Pacific Westeel pacificwesteel.com 866-473-3472 Oakville, Ontario, Canada x x x x
Penco Products pencoproducts.com 800-562-1000 Skippack, Pa.
Ridg-U-Rak ridgurak.com 866-479-7225 North East, Pa. x x x
Schaefer Systems International
ssi-schaefer.us 800-876-6000 Charlotte, N.C. x x x x
SPG (formerly Jarke)
spgusa.com 800-722-5255 Prospect Heights, Ill. x x
SpaceRak spacerak.net 800-336-3926 Wills Marysville, Mich. x x x
Speedrack Products Group
speedrack.net 800-752-7352 Sparta, Mich. x x x
Steel King steelking.com 800-826-0203 Stevens Point, Wisc. x x x
Twinlode twinlode.com 800-535-6719 South Bend, Ind. x x x
Unarco Material Handling
unarcorack.com 800-862-7261 Springfield, Tenn. x x x
Wireway Husky wirewayhusky.com 800-438-5629 Denver, N.C. x x
Primary pallet rack suppliers Most rack suppliers provide all of the basic pallet racking systems: selective; double-deep; drive-in; drive-through; gravity flow and push-back rack. Choice of steel and method of construction vary by company.
MMH1102_ER_Racks.indd 62 2/9/11 9:26 AM
mmh.com Modern Materials Handling / F e b r u a r y 2 0 1 1 63
reason, any increase in the price of steel will drive a percentage increase in the cost of the finished rack.
Rack systems can generally be divided into two broad categories: low-density systems that allow easy access to product, or high-density systems that make better use of space but limit access to stored
product. Here’s look at what the different sys-tems offer.
LOW-DENSITY RACKSingle-deep rackSingle-deep rack, or selective rack, is the most common type used in warehouses and distribution cen-ters. Since loads are stored one pallet deep, this is the low-est density storage of any system, but it allows unimpeded
access to every pallet. It can be used in a number of aisle configurations and can be paired with any type of lift truck.
Single-deep pallet rack is also the least expensive rack option. According to “Rules of Thumb,” a pricing guide published by TranSystems, standard
selective pallet rack costs about $50 to $75 per pallet position.
Double-deep rackAptly named, double-deep rack stores one pallet load behind another in a structure that’s twice as deep as single-deep. This design doubles storage, but it limits access and flexibility.
To access the rear pallet load, the front pallet position must be empty. Double handling is necessary unless pal-lets are stored on a last-in/first-out basis. In most cases, two pallets with the same product are stored in a slot of a double-deep rack, which limits flexibility and requires a deep-reach lift truck to access loads in the rear position.
“Rules of Thumb” lists double-deep rack at $65 to $90 per pallet position.
HIGH-DENSITY RACKDrive-in rackDrive-in rack can be configured to store loads four or more deep, creating very
this high-density pallet rack storage system uses an electric cart to load and unload pallets, saving time and minimizing forklift incidents.
modern Equipment 101: Pallet rackA primer for warehouse/DC managers
Streamlined movement in and around pallet racking is crucial to an opera-tion’s overall success. “About 80% of
all industrial storage is on pallet rack,” says Frank Ceriello, vice president of sales for Aigner Index (www.aignerindex.com). “The ultimate goal is to know where everything is—all of the time.”
Bar codes provide a wealth of product data, but in a harsh warehouse environ-ment, the quality of a bar code label can be compromised if it isn’t protected properly. An unprotected bar code label can be damaged by dust, dirt, grease, moisture or smudged label ink. Then it might not scan or it might scan inaccurately. Either scenario can cause serious and expensive shipping and inventory problems, not to mention the impact it could have on cus-tomer relations.
One simple solution for bar code pro-tection is clear insertable plastic label hold-ers. Available in many styles, these holders typically cost less than 5% of the total ware-house expenses and can generate returns in improved productivity, inventory accu-racy, knowledge of product location, and flexible designation or location changes.
Once product is located, tracking its
movement and operator performance can also pay off big. “Complete visibility to vehicle movement can bring gains in labor productivity, fleet optimization and safety,” explains Sarah Brisbin, vice presi-dent of marketing for Sky-Trax (www.sky-trax.com).
To determine the location of a fork-lift, a sensor mounted on top of the vehicle reads the optical position mark-ers mounted in the racked area. The system can pinpoint the forklift to within a square inch the facility.
Special system reporting packages can measure distances traveled and time taken to complete a task. Traffic reports can identify bottlenecks and collisions. With this tracking system, users can go back and replay the data to see which truck contacted the rack and why. It can also determine who was driving and what was he carrying. Finding the answers to these ques-tions quickly could identify the need for additional operator safety training, uncover a process flaw, or identify a damaged rack that requires immediate attention to prevent disaster down the road.
Protect the code, track the load
Plastic label holders (top) can protect the bar codes on pallet rack. Ceiling-mounted sensors (bottom) can help locate a forklift and identify the cause of rack damage.
MMH1102_ER_Racks.indd 63 2/9/11 9:26 AM
64 F e b r u a r y 2 0 1 1 / Modern Materials Handling mmh.com
dense storage. For example, a drive-in system that stores pallets four high and five deep can hold 20 pallet loads in each bay.
In a drive-in system, lift trucks drive into the front of a storage bay, place a load in the designated position then back out. The rack is designed with-out traditional beams across the bays so lift trucks can maneuver in and out. Instead, pallets rest on rails that run along the inside of the bay, perpendicu-lar to the aisles.
Pallets are stored on a last-in/first-out basis. Each bay is typically dedi-cated to a single product, so drive-in rack is best used for storing large quan-tities of the same product. They work well where an entire bay of product is moved at once, such as in staging prod-uct for shipping.
According to “Rules of Thumb,” stan-dard drive-in rack costs $80 to $105 per pallet position for systems two loads deep, $75 to $105 for three loads, and $75 to $100 for four or more loads deep.
Drive-through rackDrive-through rack is almost the same as drive-in, except that drive-through rack allows lift trucks to enter from either end. This means an aisle is required at both ends of the structure, but it increases access to pallet loads and can be loaded from one end and emptied from the other, enabling first-in/first-out product rotation.
According to “Rules of Thumb,” drive-through rack costs $80 to $120 per pallet position for systems two loads deep, $80 to $115 for three loads, and $80 to $110 for four of more loads deep.
DYNAMIC STORAGEGravity flow rack Gravity flow rack combines a stationary rack structure with skate wheel or roller conveyor to create a dynamic storage sys-tem. Pallets are loaded into the back end of the rack then travel down the slightly inclined lane of conveyor so they can be retrieved from the front of the system.
Flow rack systems provide high-density storage by storing product many pallets deep. Because each layer of flow rack is typically dedicated to a single product, these systems offer less stor-age flexibility than selective rack but more than drive-in or drive-through.
This is a good option for storing dated products because it allows easy rotation of inventory on a first-in/first-out basis. It can be used for picking by the piece, carton or pallet. Carton flow rack that stores individual cartons are also avail-able from many manufacturers.
Because there is more engineering involved in creating flow racks, they are more expensive than selective rack. According to “Rules of Thumb,” flow rack costs $135 to $260 per pallet posi-tion for systems two loads deep and $250 to $400 for three or more loads deep.
Push-back rackPush-back rack combines a stationary rack structure with nested carts that move along inclined rails. The first pal-let, which is loaded from the front, is placed on top of the cart. When the second pallet is loaded, it pushes back the first pallet, exposing the second cart, and so on.
Usually configured two to five pal-lets deep, these systems offer dense storage. Like flow rack, push-back rack does not require a lift truck to enter the
racking structure or require an entire bay to be dedicated to one product. Unlike flow-rack, however, push-back rack manages inventory on a last-in/first-out basis and requires less space than flow-rack because rear access is not necessary.
According to “Rules of Thumb,” push-back rack costs $110 to $140 per pallet position for a double-deep system and becomes more expensive as carts are added—$130 to $170 for three deep, $155 to $200 for four deep, and $175 to $220 per pallet position for a system five loads deep.
Protect your investmentWith so much riding on your rack, it’s wise to protect your investment. Rack damage is the biggest risk to users, so replacing damaged components is critical, says Steel King president Jay Anderson, who is also the current president of the Rack Manufacturers Institute (RMI, www.mhia.org/indus-trygroups/rmi). All rack manufacturers offer a variety of options and acces-sories that reduce potential damage to rack structure, he says, and advises making the investment in protection.
Don’t skimp on protection or preven-tion. “Nothing lasts forever, and wear and tear can take its toll,” adds Curry. “Actually walk the aisles and inspect your rack fre-quently. This preventive step could save a major headache later on.” M
modern Equipment 101: Pallet rackA primer for warehouse/DC managers
If good rack goes bad, the results can be catastrophic, even deadly. So pallet rack suppliers have established strict techni-
cal guidelines to ensure product integrity and overall safety. To be sure the rack you’re considering meets these guide-lines, look for the R-Mark.
The R-Mark Certification pro-gram is administered by the Rack Manufacturers Institute (RMI, www.mhia.org/industrygroups/rmi), an industry group within the Material Handling Industry of America (MHIA). To earn the R-Mark, rack manufactur-ers must submit sets of product data which is studied by RMI engineers to
ensure the suppliers’ testing, calcula-tions and resulting rack capacities meet the most current standards.
Only after product data is shown to meet the guidelines does RMI issue the R-Mark seal. Manufacturers are then authorized to use the R-Mark seal on published capacity charts and designs and display it on products built according to those designs.
You can visit the RMI Web site for the latest versions of rack standards (including MH16.1-2008-Specification for Industrial Steel Storage Racks and MH26.2-200-Specification for Welded Wire Rack Decking).
R-Mark marks the rack
MMH1102_ER_Racks.indd 64 2/9/11 9:26 AM
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66 F e b r u a r y 2 0 1 0 / Modern
modern special report
Reader survey:
When it comes to automated materials han-
dling equipment, end users are most likely
to turn to conveyor to speed up the flow of
product in their plants, warehouses and distribution centers.
Take crossdocking, for instance. Without conveyor, it’s hard
to imagine how else to get thousands of cartons from the
receiving dock to the shipping dock in 10 minutes or less.
It’s not uncommon to have several miles of conveyor in the
largest retail distribution centers.
By Bob Trebilcock, executive editor
Conveyors are the most used form of
automation in today’s plants and distribution
centers. Modern readers told us how they’re
putting the technology to work.
Conveyor technology
MMH1102_SpRpt_Conveyors2.indd 66 2/8/11 2:20 PM
PH
OTO
GR
AP
HY
BY
NA
ME
Modern Materials Handling / F e b r u a r y 2 0 1 0 67
As the materials handling industry emerges from a recession and looks to grow again, how are Modern readers planning to deploy conveyor technologies in the future and what are their purchase plans? To find out, we surveyed e-mail subscribers of Modern as well as a sample of recipients of our e-news-letters. We received answers from 269 qualified respondents, defined as a reader who buys or uses conveyor for their company. The respondents represented a range of companies, both large and small, with 26% reporting revenues of more than $500 million, 20% reporting revenues of more than $100 million and the remainder under $100 million.
Respondents also represent a mix of manufacturers, distributors and warehouses associated with manufacturing. The breakdown is:• 62%ofthoseplanningtopur-
chase new conveyor will use it in a manufacturing plant,
• 40%willuseitinadistributioncenter, and
• 30%willuseitinawarehouse.
Here are the most important results.
From belt to towlineFrom belt to towline conveyors, the conveyor industry offers a diverse mix of products, and Modern’s readers employ them all (see chart for complete listing). • 80%areusingbeltconveyor.• 63%areusingrollerconveyor.• 62%areusingaccumulation
conveyor.• 53%areusingmotor-driven
roller conveyor.• 47%areusingchainconveyor.
While fewer readers have installed sortation systems, the mix among those who have is fairly evenly divided among the different speed offerings, measured in car-tons per minute (cpm). • 26% are using medium speed
sortation (50 to 150 cpm).• 24%areusinghighspeedsorta-
tion (150 cpm and up). • 20%areusingslowspeedsorta-
tion (up to 50 cpm). When it comes to future con-
veyor purchases, the picture
remains much the same for the next18months:• 60%plantopurchasebelt
conveyor. • 41%plantopurchasemotor-
driven roller conveyor. • 40%plantopurchaseroller
conveyor. • 39%plantopurchaseaccumu-
lation conveyor. • 30%plantopurchasechain
conveyor.
Planning for the futureCaution seems to be the watch-word when it comes to future investments in conveyor and sor-tation systems. With the economy beginning to grow again, a segment of Modern’s readers is planning to spendmore (23%)or the same(30%)onconveyoroverthenext18months than they spent in the last 12 months. Another 22% are tak-ing a wait-and-see attitude before planning any future investments.
And, those investments may be modest. Sixty-one percent report that they will spend $100,000 or less including 37% who say they
Conveyor technology
MMH1102_SpRpt_Conveyors2.indd 67 2/8/11 2:20 PM
68 F e b r u a r y 2 0 1 0 / Modern Materials Handling mmh.com
will spend less than $50,000 in 2011; only 14% expect to spend more than $1 million on conveyor technologies over the next 18 months. The median increase for those expecting to spend more is 20% over their 2010 budgets.
On a more positive note, only 15% report that their overall materials han-dling budgets have been cut for 2011 and only 8% say they will be spending
less in 2011 than in 2010. That said, end users appear to be
looking for growth in 2011, with 29% reporting that their conveyor purchases are part of a larger integrated system; meanwhile, 39% say they are purchas-ing the equipment for a new facility and 61% say their purchase is part of an expansion project.
The majority of those purchases
come directly from a conveyor manu-facturer (54%) or conveyor distributor (39%).
The same holds true when it comes to replacement or spare parts, with 46% purchasing directly from a manu-facturer or a manufacturer’s Web site (25%), while 38% purchase from their distributor or use their distributor’s Web site (16%).
Reliability counts Automated materials handling systems are mission critical. If a lift truck breaks down, another lift truck can pick up the slack. If a conveyor goes down, a facil-ity may be down until that conveyor is back up and running.
It comes as no surprise then that reliability was considered “very impor-tant” (72%) or “important” (25%) by more readers than any other attribute. The reputation of the supplier was a distant second, ranked as very impor-tant by just 39% of respondents. Price was also ranked as very important by 39% of respondents.
Conveyor users also appear to stick with the tried and true: Just 19% of our readers ranked leading edge technol-ogy as a very important factor in their buying decision, while 31% ranked it as relatively unimportant.
When it comes to features, Modern’s readers value individually powered zones (57%); design flexibility (55%); low energy/power consumption (53%); low noise emission (48%); and intelli-gent conveying features (32%) in their systems.
Up and running Conveyor manufacturers, like lift truck providers, have been developing new maintenance programs for their cus-tomers. Still, Modern’s readers are mostly taking care of business when it comes to keeping their conveyor sys-tems up and running. • 81%usetheirowncrewformainte-
nance.• 8%haveaservicecontractwithan
OEM/supplier.
How is the economy impacting your spending onconveyors and/or conveyor parts and accessories?
Will be spending about the same asas in 2010 on conveyors in 2011 30%
Will be spending more on conveyors in 2011 23%
We are taking a 'wait-and-see' approachand not planning to invest at present 22%
Overall materials handling budgethas been cut in 2011 15%
Will be allocating more on maintenance 10%
Will be spending less on conveyors in 2011 8%
Which of the following types of conveyorsare currently in use at your facility?
Belt
Roller
Motion-driven roller
Accumulation
Gravity flow
Chain
Pallet
Spiral
Medium-speed sortation
High-speed sortation
Slat
Low-speed sortation
Power-and-free
80%75%
63%74%
53%59%
52%47%48%
58%47%
38%34%
29%26%
23%26%
21%24%
18%22%
19%20%
25%20%
26%
December 2010
February 2010
Note:Low Speed Sortation: up to 50 cpmMedium Speed Sortation: 50-150 cpmHigh Speed Sortation: 150 cpm and up
modern special report
MMH1102_SpRpt_Conveyors2.indd 68 2/8/11 2:20 PM
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• 5%haveaservicecontractwithathirdparty.Only10%reportedthattheyarecon-
sideringoutsourcingtherepairandmain-tenanceoftheirconveyorequipment.
Sustainability in the balance Sustainabilityisoneofthehottesttopicsinbusinesstoday,and,dependingontheorganization,oneofthemostcontrover-sial.When it comes to green conveyortechnologies,Modern’s readers seem toreflectthosedivisions.
Only 3% report that energy effi-ciencyisoflittleimportanceasitrelatesto their conveyor systems, while 40%report that it is somewhat important;34% say it is very important; and 16%sayitisextremelyimportant.
At the same time, only handful ofcompanieshavereceivedtaxcreditsforsuchaninstallation:• 52%reportthattheyplantoinves-
tigatetaxincentivesforenergy-effi-cientsystems.
• 38%saytheyhavenoplanstoinves-tigatetaxincentivesforenergyeffi-ciency.
• 10%saytheyhavealreadydoneso.M
How much do you estimate you will spendon conveyors and/or conveyor parts andaccessories in the next 18 months?
Approximately how much did you spendon conveyors and/or conveyor parts andaccessories during the last 12 months?
$1 million +
$500K-$999
$100K-$499
<$100K
February2007
62%
22%
6%
10%
$80,000
$263,000
Median $
Average $
February2008
54%
26%
7%
13%
$92,000
$321,000
February2009
65%
18%
7%
9%
$76,000
$255,000
February2010
61%
20%
6%
13%
$81,000
$297,000
December2010
61%
18%
7%
14%
$75,000
$300,000
Spent in thelast 12 months
64%
18%
7%
11%
$55,000
$261,000
Is this a new or expansion installation?
60%
40%
February2007
68%
32%
February2008
63%
37%
February2009
67%
33%
February2010
61%
39%
December2010
New
Expansion
How important is energy efficiencyas it relates to your conveyor system?
Extremely important
Very important
Somewhat important
Not very important
Not at all important
16%17%
34%34%
40%38%
7%9%
3%3%
December 2010
February 2010
90%of respondents
believe thatenergy efficiency
is important
modern special report
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Crossdock fuels growth at DotsBY maiDa napoLitano, CONTRIBUTING EDITOR
by banking on a combination of crossdocking and flow-through distribution to rapidly
provide its customers with the latest fashions at affordable prices, the retailer has
emerged as a force to be reckoned with in a highly competitive retail landscape.
There’s no wasting time at Dots. This Ohio-based fashion retailer uses a unique sourcing model to quickly interpret the lat-est fashion trends into
everyday-wear apparel for women. And because what’s hot today may not be hot tomorrow, the retailer’s distribution team needs to immediately dispatch these lat-est looks from its suppliers to more than 400 stores within a 26-state radius—and do it in a fl ash.
How do they make this happen? Lisa Akey, Dots’ divisional vice president of distribution and lead project manager of the company’s new, state-of-the-art, 193,000-square-foot facility in Glenwil-low, Ohio, shares her secret: “At the end of the day, we have almost nothing that stays in the building. And the rest that does doesn’t stay long.”
Once received, 20% of Dots’ volume is automatically crossdocked to shipping—sometimes in as little as 6 minutes—via a network of conveyors and conveyor sorta-tion systems. Within 24 hours, the other 70% has been diverted to two high-speed unit sorters that fl ow-through bulk mer-chandise to individual stores, while the remaining 10% of mostly basic, non-sea-sonal items, goes into storage for future replenishment.
By banking on a combination of cross-docking and fl ow-through distribution to rapidly provide its customers with the latest fashions at affordable prices, Dots has emerged as a solid force in a highly
competitive retail landscape. Over the next few pages, we’ll learn how Akey and the Dots logistics team have put this time-tested distribution method to work to keep the retailer one step ahead in a challenging and fi ckle market.
growing painsSince the late 1980s, Dots has been dis-tributing merchandise to its stores from a manual, more conventional facility, 3 miles from its current location. Although this older facility afforded the retailer many functional years, by 2005, much of the equipment was nearing the end of its life, putting limitations on operational growth and effi ciency. In fact, it took this previous DC three to four days to get a store order out the door. Vendors commu-nicated via faxes and e-mails, and there was no receiving sorter. All carton-label-ing from receiving to shipping was manu-ally applied.
When you boil it down, the company actually had been manually crossdock-ing for years—just nowhere near as fast and as effi cient as they’re doing it now in the new DC. “Our previous system had no EDI (electronic data interchange) and limited, outdated automation that restricted our throughput speed and capacity,” recalls Akey. “There was a lot of double and triple handling just to get orders out the door.”
With only one crossdock-capable door, many crossdock orders would be unloaded, then staged, then put in a queue before actually getting processed—
a clear departure from cross docking’s “expedite immediately” philosophy.
To distribute bulk apparel to the individual stores, Dots was using a 10-year-old, put-to-light system that they had simply outgrown. “To support the volume demand, we had to go to extended shifts and work a lot of over-time,” notes Akey.
The clock was also ticking because the put-to-light system’s capacity was limited to 500 stores. In 2005, they were already sitting at 350 stores and growing at a rate of 40 new stores per year. “These outdated systems and their inability to support future store growth is what ultimately pushed us to move forward with the process of designing a new distribution system,” says Akey.
pLanning anD eXeCutionSo in March 2006, Akey began the process of selecting a consulting fi rm that could help Dots design a new dis-tribution system. After three months of extensive interviews, site visits, and ref-erence checks, Dots decided to partner with California-based SDI Industries, a systems integrator and solutions pro-vider that had extensive experience in the fashion retail industry. To aid in the analysis and establish best practices benchmarking, SDI brought in another California-based consultant, Dennis Green from Green & Associates.
For several months, the team col-lected data; audited current processes from source, to DC, to store; and ana-
s72 F e b r u a r y 2 0 1 1 / Modern Materials Handling mmh.com
Crossdock fuels growth at Dots
A SPECIAL SUPPLEMENT TO:
W A R E H O U S E & D C
MMH1102_SUPstoryDOT.indd 72 2/9/11 9:28 AM
Crossdock fuels growth at Dots
Lisa Akey, divisional vice president of distribution, Dots, Steve Haskell, vice president and lead implementation manager, SDI
Photographs by Roger Mastroianni
mmh.com Modern Materials Handling / F e b r u a r y 2 0 1 1 s73
lyzed business projections before nailing down the final detailed system design in November 2006. “The process was slow and tedious,” says Akey. “However, it was critical to define every nuance of the system, including all system specifi-cations and software interfaces. Without this level of detail, a successful imple-mentation could not have happened.”
In May 2007, after a lengthy study of the present building and available
alternative sites, Dots made the deci-sion to build a completely new office and distribution center in Glenwillow, Ohio. In February 2008, groundbreak-ing took place and SDI was selected to install and implement the entire dis-tribution system.
In September 2008, with only the floor and the building shell in place, SDI began mechanical installation of the new distribution system. “The
schedule was aggressive and followed closely behind the actual construction of our new building,” says Akey.
By January 2009, SDI completed the installation of the equipment and immediately started hands-on training. “Because the unit sorters were perhaps the biggest change from the old system, we arranged for Dots to send their peo-ple to our other clients’ sites to literally work on their unit sorters,” says Steve
MMH1102_SUPstoryDOT.indd 73 2/9/11 9:28 AM
Haskell, SDI’s vice president and lead implementation manager. From Janu-ary to April, SDI’s software team was also onsite to train Dots personnel and offer systems support.
Because Dots did not really have a true warehouse management system (WMS), “this became a more involved, all-encompassing warehouse control system (WCS) and software project on our end,” adds Haskell. “The new WCS is totally tailored to match Dots’ sys-tems with almost no changes on their side.” Transition to the new DC was complete by May 2009.
Keys to suCCessAccording to Akey, installation of the automated equipment and software was only half the battle. The true key to a successful crossdock is the auto-mated exchange of information through EDI between Dots and its many ven-dors even before the product physically
arrives at the receiving door. Dots’ IT department had the unen-
viable task of getting its many vendors and suppliers onboard with EDI. “The EDI team has now transitioned a sig-nificant portion of our vendors to EDI, representing about 50% of the units processed with the goal of impacting 80% of units this year,” reports Akey.
Dots also dedicated a substantial amount of resources on extensive train-ing and building job aids for its internal allocation and merchant teams. “These job aids guide the vendors to identify the best way to pack a purchase order (PO) based on a category and allo-cation plan,” says Akey. “Everything begins with the correct PO. If the PO is not written correctly or if the vendor ASN (automated ship notice) does not match, everything stops.”
Opportunities to build crossdock cartons are also identified at this point. Akey lists denim, fall sweaters, outer-
wear, footwear, and other bulky items that tend to quickly fill store cartons as naturals for crossdocking.
How tHe Dots system worKsThe new operation is a blend of the most advanced conveyor and mechani-cal technology with the latest systems in information processing and control soft-ware. It is this combination of hardware and software that allows the retailer to achieve its goal of same-day distribution.
A vendor ASN is received either via EDI or e-mail 24 hours in advance of the physical merchandise arriving. Once allo-cations are received, cartons are unloaded onto one of six receiving conveyors. They flow easily through the system with either the vendor-applied License Plate Number (LPN) or, in the case of man-ual ASNs, LPNs that have been printed onsite and have been manually applied.
Cartons then flow quickly to the merge and shipping sorter where they can be
1 2 3
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Special Supplement: Warehouse & DC
MMH1102_SUPstoryDOT.indd 74 2/9/11 9:28 AM
diverted to one of 14 possible destinations: eight shipping lanes, one automated print-and-apply lane, two unit sorter induction lanes, one VAS lane, one new store/storage lane, and one no-read lane.
In the old system, Dots had been crossdocking more—up to 45% of its unit volume. With the new unit sorters in place, however, it became a strategic decision to more precisely flow mer-chandise to stores based on specific needs up until the point of allocation while still creating an efficient, cost effective outbound carton.
“As we’ve done more analysis of each store and its sales history, we’re replenishing only what that store actu-ally needs,” says Akey. “That may some-times be less than a crossdock carton.” As a result, there is now a smaller ratio of units being crossdocked, from 45% in 2005 down to 20% in 2010, and more units (up to 80%) being processed through the unit sorter.
reaping tHe benefitsThis shift to automation has predict-ably increased Dots’ capacity by leaps and bounds, allowing the retailer to now easily support up to 700 stores within their current footprint. Volume throughput from the two unit sorters almost triples that of the previous put-to-light system (5,500 vs. 1,900 units/hour). The new shipping sorter now processes up to 80 cartons per minute (cpm), more than three times the old sorter that operated at 25 cpm.
Productivity increased 20% versus 2008 statistics with a 30% increase planned for 2011. The company also achieved a 20% reduction in labor costs. “For the past few years, suppli-ers have been forced to pick-pack for retailers at supposedly no cost,” notes Haskell. “Dots now has the flexibility to call on vendors that can’t or won’t do it, while keeping control on distribution costs and quality.”
With minimal storage requirements and only 70,000 of the 145,000 square feet of DC space in active use, there’s substantial room for expansion or special projects. “At some point, the ultimate plan is to position ourselves to go to e-commerce,” says Akey. For now the retailer continues to work on supply chain efficiencies to maximize their system.
What’s been critical to this project’s success? “Choosing the right integra-tor,” adds Akey. “One who is committed to you and who will provide you with great ideas and solutions.” Second, she says, is “planning and more planning; training and more training.”
Haskell agrees. “When you go auto-mated and you tie the front door to the back door in 6 minutes, you better know how to run it.” M
Maida Napolitano is a Contributing Editor to Modern Materials Handling.
4 5
1. Workers unload cartons from trailer. 2. Inbound cartons travel to merge. 3. After merge, crossdock cartons enter print-and-apply stations, then are conveyed to shipping lanes. 4. After merge, cartons for store distribution get processed at the unit sorters. 5. At unit sorters, individual pieces travel on trays and get sorted to specific store cartons. 6. When store carton is full, worker closes carton. 7. Worker scans label on store carton then pushes carton to center takeaway conveyor. 8. Store carton travels to shipping lanes. 9. Crossdock and store cartons are diverted to one of eight shipping lanes.
9
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mmh.com MODERN MATERIALS HANDLING / F E B R U A R Y 2 0 1 1 77
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AC-powered trucks conserve, regenerate power for longer run timesOffered in capacities from 4,000 to 6,500 pounds—including a new 5,000-pound model—the 8-Series four-wheel lift trucks for indoor handling are AC-powered with subsystems that conserve or regenerate power to maximize operational productivity between battery charges. The motor compensates for battery deple-tion for longer run times and consistent power output. Regenerative braking, coast control, and plug-and-foot braking extend run times and prolong brake component life. To reduce maintenance costs, there are no motor
brushes, springs, commutator or wearable parts to service and replace. Operator ergonom-ics is enhanced with expanded leg room, four-way adjustable suspension seat, joy-stick hydraulic con-trols, multifunction
digital display and ample visibility from the driver’s seat. Toyota Material Handling U.S.A., 800-226-0009, www.toyotaforklift.com.
FOCUS ON Lift trucks
Stand-up counterbalanced truck is 100% AC-poweredThe platinum SCX series of stand-up coun-terbalanced trucks is offered in three lift-ing capacities up to 4,000 pounds. Fully AC-powered, the vehicles feature two inde-pendently controlled drive motors and drive units integrated with a continuous feedback system for faster acceleration and high travel speeds, both loaded and empty. The system also conserves energy to extend battery run
times with standard auto-power off and regenerative braking. Other features include automatic self-check, smart LCD meter panel with on-board diagnostics, standard thermal protection on motors and con-trollers, and rugged steel chassis and enhanced mast. Nissan Forklift, 815-568-0061, www.nissanforklift.com.
VNA truck lifts 4,000 pounds up to 360 inches highCapable of handling up to 4,000 pounds, the four-wheel B40VAC very narrow aisle truck features rear-wheel drive, 15% gradeability, fast travel speeds and enhanced power efficiency. A 32-inch wide front axle as well as a slim line, three-stage mast enable the truck to stack loads with footprints measuring 48 x 40 inches from 72-inch aisles. Loads can be lifted up to 360 inches high. Bendi/Landoll, 800-428-5855, www.landoll.com/mhp/bendi_electric.
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2514
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3-wheel counterbalanced trucks maximize operator comfortTo enhance ergonomics, the 4150 and 4250 stand-up counterbalanced lift trucks incorporate greater visibility, increased maneuverability, a shorter head length, dual steer tires, and responsive suspen-sion. Offered in load capacities from 3,000 to 5,000 pounds, operator comfort is ensured by a smooth-ride suspension and cushioned floor mat that isolates operators from impact and vibration. The suspension adapts automatically to each
operator’s weight and employs only nine parts for sim-ple maintenance. The three-wheel trucks perform right-angle stack-ing maneuvers in less total area, with dual-steering that allows one wheel to counter-
rotate during turns for a
shorter turn radius
and reduced tire loading and steering friction. the raymond Corp., 800-235-7200, www.raymondcorp.com.
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FOCUS ON Palletizers
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lifts feature galvanized constructionFor safe transfer of loads from truck bed to dock without ramps or inclines, Dura-Dock loading-dock lifts are offered. The units come in 5,000- and 6,000-
pound capacities and feature galvanized, corrosion-resistant base and legs. Rising from grade level to a maximum height of 59 inches, the lift may be mounted in a concrete pit. Platform sizes range from 6 x 8 feet to 8 x 12 feet. Features include a weatherproof pushbutton control with 20 feet of coiled cord, a diamond-tread, steel platform with beveled toe-guards, and
removable steel handrails. southworth Products, 207-878-0700, www.southworthproducts.com.
Control dock environment with sliding softwallsCreating better environmental control, flexible sliding softwalls slide open or closed with minimal effort to create sepa-rate zones in loading dock staging areas. The curtain walls also improve cleanli-ness, increase security and contain odors, fumes, dust or noise. Made of heavy-duty industrial vinyl, the units are custom fab-ricated for each application, and can be reconfigured as facility layout or environ-mental control needs change. Mountable to the existing ceiling structure, a heavy-duty track and trolley system supports the walls. Zoneworks, 800-553-4834, www.zoneworks.com.
Centralized dock power source lowers building costsTo cut the complexities and costs of new loading dock installations, the CentraPower unit reduces the number of hydraulic pumps, disconnects and associated power feeds by a factor of 10 to 1. Locating the hydraulic power source in a conve-nient location inside the building yields cleaner access, sim-plified maintenance and lower costs. The system features a full backup pump and motor system to ensure continuous up-time. systems inc., 800-643-5424, www.docksys-temsinc.com.
Cabinet for lean manufacturingFor better workspace organization and management, the 5S cabinet offers clear acrylic doors for instant visibility and at-a-glance accounting of tools and parts at point of use to support lean manufacturing philosophies. The durable cabinet case fea-tures metal pegboard inserts. Alternately, solid hinged doors with additional peg-board storage may be specified. Stanley Vidmar, 800-523-9462, www.stanleyvidmar.com, Booth 2532.
44 M A R C H 2 0 1 0 / MODERN MATERIALS HANDLING mmh.com
Abuse Resistant Belts work where others fail.Super Strong Joints are virtually unbreakable.High Tension Belts move heavier loads.Super Red Belts double conveyor capacity.
Dura-Belt 800-770-2358 614-777-0295Fax: 614-777-9448 www.durabelt.com
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New Split Line-shaft SpoolsHigh precision. Reasonable price.Easy to install. Zero downtime. Can be locked to shaft. Eliminatesneed for keyed spools and shafts.
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Software directs, analyzes paperless picking activityExecutives, managers and supervisors can easily view pick rate productivity, accuracy and throughput with the version 6.0 release of LP dash-board. The software displays real-time, updated key performance indicators with drill-down granularity for facility, area, zone and employee-level views. Featuring a rich graphi-cal interface with drag-and-drop widgets for custom template views of performance data, the system offers an automatic slide-show style display of multiple, user-configured templates. Lightning Pick Technologies, 262-250-2143, www.lightningpick.com, Booth 1543.
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Vertical storage systemFeaturing a stabilized shelf system with high storage density at an afford-able price, the motorized vertical pan carousel offers storage and retrieval of inventory with push-button control. The system delivers inventory to the opera-tor, yielding retrieval time savings up to 90%. Included standard are lifetime sealed bearings, shielded motors, secu-rity keypad, one-touch forward/reverse, wire mesh guarding and obstruction detectors. Vidir Machine, 800-210-0141, www.vidir.com, Booth 3018.
Treatment prevents mold growth on palletsE-fusion mold and mildew resistant coating and treat-ment system for wood pallets inhibits the growth of mold, preventing product recalls and refused ship-ments. The treatment bonds with wood during an elec-trostatic application process, making it ideal for pallets used in food and beverage handling, consumer prod-ucts, pharmaceuticals and paper products. X-Mold, 866-581-6653, www.xmold.net, Booth 625.
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FOCUS ON dock equipment
Voice+Laser driverless vehicles have industrial grade laser guidance and incorporate voice-directed picking, leaving operators with their hands free to maximize case picking pro-ductivity. At the start of an order, the truck delivers a new pallet to the picker. Then, it automatically moves
with the voice-equipped picker as they verbally confirm picks, and transports the completed pallet to shipping while the next truck brings a new pallet to the picker. During peak periods, pickers with manual pallet trucks can work in conjunction with the system to handle additional throughput. As requirements change, routing plans can be updated and additional vehicles can be added or transferred between sites. Dematic, 877-725-7500, www.dematic.us.
Low-cost AGVs handle up to 4,000 poundsCapable of maneuvering and tow-ing loads throughout a production space, a series of low-cost automatic
guided vehicle systems can be con-trolled with traffic control naviga-tion software. The vehicles come in capacities ranging from 500 pounds to 4,000 pounds, making them ideal for handling smaller loads and increased volumes without additional staff. Features include multiple path programming, a retractable towing pin, remote communication, and
Driverless trucks with voice directed picking
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AGVs
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Floor-level palletizer with extended accumulation tableCombining the economy and accessibility of a floor-level palletizer with speeds associ-ated with high-level machines, the 72AE palletizer incorporates an extended accumula-tion table that allows continuous layer forming during transfer and stacking. This feature increases the volume to more than 35 units per minute. It also includes energy-efficient electric motors, quiet operation and pre-programmable layer patterns and pallet con-figurations for easy startup and control. The unit can palletize cases, trays, bags or totes. Automatic changeover is directed by the operator touch-screen panel. For flexibility, intelligent control accepts new or modified pallet, layer and product configurations from authorized personnel, with all operating parameters independently adjustable. a-B-C Packaging Machine, 800-237-5975, www.abcpackaging.com.
energy-efficient workstationThe electric workstation lift for palletizing offers quiet, energy-efficient operation. The area beneath is large and open for easy straddle stacker access to the platform. For easy main-tenance, standard 115-volt power units are rear mounted for access when the lift is in the down position. The lifts are offered as an alternative to pneumatic and hydraulic powered solutions for applications where air is not easily available and hydraulic fluids cannot be tolerated. advance lifts, 800-843-3625, www.advancelifts.com.
robot works in tight spaces, delivers 20 cycles per minuteDelivering speeds up to 20 cycles per minute, the EC-171 high-speed robotic palletizer is equipped with a built-in collision detection system. Incorporating a large working enve-lope with small rotation radius and energy efficiency, the robot works in tight space con-strictions at a high rate of throughput. A 10.5-inch color touch-screen is included for human interface control (no laptop required). The system offers onboard diagnostics, advanced
programming platform, and up to 400 different pre-programmed recipes. american-newlong, 317-787-9421, www.american-newlong.com.
MMH1010_FocusOn_Prod.indd 38 10/12/10 1:59 PM
Motorized Storage & Retrieval Solutions
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Maneuverable tuggers pull up to 15,400 poundsOffering maximum strength and dura-bility, the CTX 40 and CTX 70 utility tuggers include gear type steering for long-term reliability with easy maneu-verability enhanced by headlights and turn signals. The AC-powered vehicles pull 8,800 and 15,400 pounds, respec-tively, and include utility cargo areas capable of carrying up to 400 pounds. For operator comfort, a full suspension seat is included. When the operator leaves the seat, the truck is disabled. When the key switch is turned on, the controller completes an auto diagnos-tic check. To prevent the tugger from rolling down inclines when stopped or started on a ramp, an anti-rollback function is included. Clark Material Handling, 866-252-5275, www. clarkmhc.com.
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Heavy-duty trucks protect operator with 3 cab stylesA line of 8,000- to 12,000-pound capacity internal combustion pneu-matic tire lift trucks is ideal for heavy-duty applications. The vehicles have a choice of three-panel cab styles to protect operators from the ele-ments. To improve uptime and lower maintenance costs in dusty or dirty applications, fully enclosed oil-cooled disc brakes may be specified. Options include attachments, foundry and brick protection and specialty tires for truck customization, extending equipment service life and mini-mizing product damage. Cat Lift Trucks, 800-228-5438, www.cat-lift.com.
Innovative SystemsSolutions
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FOCUS ON Lift trucks
Cushion, pneumatic tire lift trucksFor moderate-duty applications, the internal combustion S50CT cushion tire and H50CT pneumatic tire lift trucks include sealed electrical connectors, O-ring face seal fittings on the truck chassis, and durable transmissions. Intended to be cost-effective, no-frills vehicles, the trucks deliver high fuel economy and operator com-
fort. Both models lift up to 5,000 pounds and maneuver through tight spaces with an electronically controlled transmission for smooth direction changes. For opti-mal load positioning, an inte-gral sideshifter is an option, while electronically controlled inching adjustments give the operator better positioning control. Extra foot space, adjustable tilting steer col-umn and increased visibility enhance operator ergonom-ics. Hyster, 800-497-8371, www.hyster.com.
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truck series lifts up to 19,000 poundsOffered with a choice of engines, the Veracitor VX truck series features low fuel consumption, minimal noise, and reduced maintenance and operating costs. Both cushion and pneumatic tire classes are included. Capable of lifting capacities from 3,000 to 19,000 pounds, the trucks employ a maintenance-free, built-in stability system. The durable, rugged powertrain incor-porates computer-controlled engine and transmission, sturdy
clutch packs, and strong gears and shafts. All transmissions have smooth electronic inching to cut maintenance costs by eliminat-ing periodic adjustments. For
maximum brake life, an auto decelerator system auto-matically slows the vehicles when the accelerator pedal is released. Yale Materials Handling, 800-233-9253, www.yale.com.
Carrier divides, separates delicate componentsIdeal for use in aerospace, manufacturing and dis-tribution, the Set Top box carrier protects delicate equipment—including converter boxes and cell phones—during storage, transit and installation. The reusable carriers include dividers to separate and protect each item to reduce damage while eliminat-ing corrugated waste and associated dust. Offered in four standard sizes, the boxes range from 14 x 15 x 10 to 27 x 15 x 18 inches. Optional accessories include handles and hand holes, covers, foam cushioning, label holders and placards, or electrostatic dissipative materials. The boxes may be specified in blue, black or white. Flexcon Container, 973-467-3323, www.flexcontainer.com. POWER TRANSMISSION-PART CONVEYING
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systems. The totes’ precise dimensional consistency ensures seamless extraction, conveying and inser-tion. With a 23.6 x 15.75 inch footprint, the totes are offered in two heights: 7.8 and 11.8 inches. Straight walls provide high cubic capacity, while the units’ rein-forced bottom prevents deflection. Both internal and external surfaces are smooth for easy cleaning, and the totes resist moisture, pests, mold and fungus. They are recyclable at the end of their service life. ORBIS, 888-307-2185, www.orbiscorporation.com.
Clear bins stack, hang and organize
Autoclavable up to 250ºF and resistant to extreme cold, Clear View Ultra stack and hang bins are manu-factured from heavy-duty, high-density tri-clear poly-propylene. Molded with front, back and side grips for easy handling, the bins organize inventory with multiple large label slots. A built-in rear hanger allows the bins to be hung from louvered panels or rails. For increased bin capacity and a quick view of contents, optional clear window inserts can be added. Twenty different sizes are offered from 5 x 4.125 x 3 to 18 x 16.5 x 11 inches. Quantum Storage Systems, 800-685-4665, www.quantumstorage.com.
Containers nest and stack
Nest and stack containers save space by stacking when full and nesting when empty. Offered in a variety of materials to accommodate a range of needs, the formu-lations include resistance to chemicals, electrostatic dis-charge and degreasers, autoclavability, flame retardance, and food handling. To facilitate movement, matched dol-lies with 3-inch diameter swivel casters may be specified. Dimensions range from 25.25 x 18 x 6 inches to 42.5 x 20 x 14.25 inches and include optional lids to protect contents from dirt and damage. Molded Fiber Glass Tray Co., 800-458-6050, www.mfgtray.com.
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FOCUS ON lift trucks
aC-powered very-narrow-aisle truck with swing mastThe AC-powered, three-wheel swing mast model SLT30AC very narrow aisle truck includes enhanced control and improved power efficiency. It is offered with a quad mast that rises to 272 inches. Capable of handling up to 3,000 pounds, the vehicle may be equipped with an optional, affordable wire guidance sys-tem that is easy to set up and install. drexel/landoll, 800-428-5655, www.landoll.com/mhp/drexel.
Fuel cell powered stockpickerCapable of accommodating fuel cells, the SP 3500 stockpicker integrates a hydrogen level indicator on the dashboard dis-play, plus programmable performance settings and advanced diagnostics for the fuel cell power unit. Operators receive an alert when the fuel cell hydrogen pressure reaches a pre-determined level—between 2% and 25% of hydrogen remain-ing. Technicians can use the dashboard display to view fault codes, including the last event code, for maintenance and troubleshooting. Ideal for narrow-aisle applications, the truck can be used for pallet handling, picking at heights and trans-port. Crown equipment, 419-629-2311, www.crown.com.
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mmh.com MODERN MATERIALS HANDLING / F E B R U A R Y 2 0 1 1 81
Multi-directional reach trucks offer 5 travel programsMulti-directional reach trucks for stacking and retrieval at high lift heights—or for transporting long loads up to 26.2 feet in narrow aisles—include electric all-wheel steering. The ETV Q series offers five travel programs, from modified standard travel to rotational travel and all-wheel parallel travel. The enhanced normal travel program steers the load wheels simul-taneously with the drive tire. Other travel programs include
360-degree steering, mini-mum turning radius and rapid direction change. Operator ergonomics are enhanced by a full-suspension comfort seat with adjustment features and automotive-style ped-als. For maximum uptime, three-phase AC drive, lift and steering motors are mainte-nance-free without carbon brushes, brush springs or commutators. Jungheinrich, 877-543-6757, www.jungheinrich.com.
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MMH1102ProductFocus_LiftTrucks.indd 81 2/8/11 2:24 PM
82 F e b r u a r y 2 0 1 1 / Modern Materials Handling mmh.com
Modern: after so many years working in the materials handling industry, what brought you to MHia now?
Prest: It was the perfect storm. As you’re probably aware, I’ve been on the Board of Governors of MHIA since 1996. Three years ago, when I sold Prest Rack, this opportunity wasn’t on the radar. But, through a set of circumstances, the position opened up. I’ve always had a passion for the industry, I’ve always wanted to do something to give back and this seemed like a good opportunity.
Modern: What do you think have been the most important changes to the materials handling industry that you’ve observed over the years?
Prest: The biggest change that I have seen has been the advances made in technology. My elevator speech—what I say when people ask me about our industry—is that the materials handling industry touches everything.
What’s changing, and also what’s fascinating to me, is how our industry is broadening its reach. Historically, what we only worried about what
modern 60 Seconds with...
George Presttitle: Chief Operating Officer, the Material Handling Industry of America
location: Charlotte, N.C.
exPerience: 34 years in the materials handling and rack business
PriMary focus: Prest’s responsibilities at MHIA include trade shows and industry events, membership meetings and statistical information
happened inside the four walls of a factory or warehouse.
Today, we are still inside the four walls, but we are also logistics and we are intermodal—we literally touch everything in the supply chain. That’s exciting.
Modern: this is our ProMat 2011 show preview issue. What should
readers be looking for at this year’s ProMat?
Prest: The ProMat pitch is simple: You’ll have everything from the traditional solutions to the cutting edge and everything in between. M
To register for ProMat 2011, visit www.promatshow.com.
MMH1102_60Seconds.indd 82 2/8/11 2:11 PM
TECTON™ HANDHELD COMPUTERPURPOSE-BUILT FOR THE WAREHOUSE
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MMH0211_Ads.indd 3 2/3/11 10:19 AM
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New Avenger™ Vertical CarouselSmall Parts, Items and Inventory Vertical Carousel
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Sapient MMH Ad Avenger 1/14/11 1:55 PM Page 1
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