June 14, 2016 - Page 15 of 16

Using Sustainability to Create a Competitive Edge

Being eco-friendly is increasingly considered a social, political and economic advantage in U.S. business and industry — and, therefore, a competitive edge. Forward-thinking companies are using environmental initiatives and dedication to sustainability to create advantageous public opinion. Cutting edge, eco-friendly solutions gain customers. The extreme, sometimes almost rabid, level of dedicated customer loyalty, despite sometimes higher consumer costs, has been an unexpected benefit. An increasing number of ecologically-concerned Americans are willing to pay more for products and services that protect or sustain the environment. Interestingly, consumers view this as a way of partnering with industry to save the environment.

More industries are pursuing sustainability to reduce the life-cycle costs of parts, equipment and processes (see our July 9 post). “Anything not in a product is considered a cost; it’s a sign of poor quality,” say the authors of Green to Gold in explaining 3M’s Pollution Prevention Pays program. “As 3M execs see it, everything coming out of a plant is either product, by-product (which can be reused or sold), or waste. Why then should there be any waste?” As the authors point out, 3M views waste as unrecouped expenses and something to be avoided. The company’s goal is 100% sustainability.

Sustainability is not limited to the direct costs of business and industry. Savings can also be realized in indirect costs such as packing, transportation and other logistics considerations. Eco-friendly smart packages that reduce cardboard and filler save resources and money. Replacing gas-guzzling forklifts with energy-smart electric and motorized carts and tugs is another environmentally smart way to cut costs. Optimizing shipping loads and delivery strategies can result in significant cost savings given skyrocketing fuel prices.

Implementing a sustainable supply chain also eliminates or reduces the amount of money spent on disposal of harmful by-products, scrap and adherence to regulatory issues. In many instances, by-products previously disposed of as waste are now generating viable revenue sources for environmentally-conscious companies. Sustainability is already being used to competitive advantage by many companies who have found it a profitable way to grow market share in their industry.

Automation Is Changing Warehousing

Warehousing and distribution centers are being forced to perform more quickly than ever before and meet a growing list of unique customer requirements. Automation is the key to success.

“To get more throughput while decreasing cycle times, more facilities are turning to the strategic use of automation for picking, conveying, storage and sortation,” wrote Modern Materials Handling editor Bob Trebilcock in a May 2006 Modern Materials Handling article on warehousing systems.

Over the past decade, automated systems have moved from simple stock locator systems to islands of single-task automation to the unified, integrated systems being installed today. Automation is speeding up every aspect of warehousing, including inventory control, receiving, material movement, picking, packing and shipping. Automation allows greater volumes to be handled in shorter timeframes. Today, automation allows customization of an end-user’s needs to be accomplished with amazing speed, accuracy and efficiency.

Engineering a customer’s requirements “into the workflow” and performing them as a matter of course, is the most efficient and cost-effective way to meet specific customer requirements, Trebilcock writes in a July 2008 Modern Materials Handling article. Some examples of using automation to meet unique customer requirements:

Pick-to-light solutions ensure order-picking accuracy and maintain throughput.
Synchronizing material delivery to the production line in the same sequence as component assembly and packing saves time on the order assembly line.
Automatic print and apply processes save labor in applying shipping labels and guarantee accurate shipments.

Anything you can do to automate your warehousing or distribution operation will improve speed and accuracy for your customers and allow you to handle a higher volume while still meeting unique customer requirements.

Using CartCaddy Products to Meet Customer Requirements

In our last post we talked about automation and how it is changing the face of the warehousing and distribution industries (see our Aug. 4 post). Automation allows businesses to handle greater volumes in shorter time periods. However, a major challenge in automating operations is the accommodation of unique customer requirements. Obtaining a customer’s business can depend upon your ability to meet their unique requirements. Doing so while maintaining a cost-effective operation can require both ingenuity and skillful management of material handling resources.

Tom Kozenski, VP of product strategy for optimization firm RedPrairie, suggested in a July 2008 Modern Materials Handling article that there are two ways to handle customer requirements: increase labor or engineer them into the normal workflow. “The first brings your operations to a grinding halt,” Kozenski said, citing the extreme cost. “The second allows you to differentiate your business from the competition.”

One way of engineering customer requirements into the workflow is to coordinate the delivery of components or raw materials to the production or assembly line with their use, Kozenski noted. Delivering materials to the assembly line in the same sequence that they will be used increases efficiency and production and, thereby, cost effectiveness. A combination of powered CartCaddies and pushers allows for maximum customization of this process.

On an assembly or production line, electric CartCaddy power tugs can be used to push or pull carts loaded with customer’s specific components or raw materials. Carts can be preloaded and delivered to the line in sequence. In a vehicle assembly plant, for example, CartCaddy power tugs can be used to deliver windows, doors and other components to the appropriate point on the assembly line for sequenced installation. In a fulfillment operation, batched orders can be carted and delivered for sequenced processing. Highly maneuverable, ergonomically designed CartCaddy products maximize the load a worker can move safely, thereby limiting the number of workers involved in material delivery.

The CartCaddy electric tug or CarCaddy vehicle pusher can then move carts, equipment or vehicles from station to station down the line. CartCaddy products are available to move equipment across the floor on wheeled tugs or on a rail.

Reducing Injury Risk for Hand Truck Operators

A recent case study of the beverage industry by ergonomic consultant ErgoWeb studied injury risk factors for hand truck operators and prevention protocols. The study’s findings have obvious parallel implications for any business or industry that utilizes manual hand trucks.

The study was prompted by significant musculoskeletal stress injuries — particularly back injuries — reported by delivery workers. Similar injury rates are common in any environment where materials are constantly loaded and unloaded and where hand trucks are used to maneuver and transport materials. Affected businesses include delivery firms, moving companies, shipping operations, loading docks, groceries, retail and big box stores, warehouses, fulfillment centers, storage facilities, auto service centers, manufacturing plants, supply centers and many others.

The study found that maintenance and weight distribution issues resulted in the greatest number of operator injuries. The highest risk of potential injury was attributed to the following:

Underinflated hand truck tires which placed undue stress on the musculoskeletal system.
Unequal weight distribution of product cases increased back compressive force during lifting, increasing the risk of back injury.
Improperly located product required twisting and lifting from un-optimal heights, increasing risk of back and shoulder injuries.
Improperly balanced hand truck loads placed unnecessary musculoskeletal stress on workers.

While new loading patterns, better hand truck maintenance and improved operator training can help reduce injury risk, a far more effective solution is to replace manually operated hand trucks with ergonomically-designed electric carts and tugs. Powered carts allow a single operator to easily transport and maneuver maximum loads without risk of injury. Adjustable handholds, adjustable speed controls, adjustable beds, scissors lifts, powered platforms and other ergonomic features allow loads to be handled at optimal levels to significantly reduce the risk of musculoskeletal injury.

If you want to reduce the risk of worker injury in your facility, talk to the experts at DJ Products about replacing your outdated hand trucks with ergonomically-designed powered carts and tugs.

Process Automation Key to Logistics Success

For logistics providers competing in a tight economy, process automation is an essential strategy. A MarketInsight study just released by Hubspan, Inc. surveyed more than 200 North American logistics companies with annual revenue between $30 million and $10 billion. Process automation to streamline shared processes, achieve operational efficiency and improve collaboration between customers, carriers and distributors were identified as the most critical challenges facing the logistics industry today.

“The logistics industry recorded strong growth over the past decade due to globalization and an increased demand for imported goods,” said Robert Pease, Vice President of marketing for Hubspan. “However, the industry shifted in early 2008 due to a slowing economy, rising fuel costs and a shortage of qualified personnel. This shift drives the need for logistics companies to apply efficiencies that automate processes and streamline operations to overcome current economic hurdles.”

Incompatible systems and difficulties in integrating systems were cited as the greatest challenge by a majority of survey respondents. “In an industry driven by efficiency, it is surprising that so few logistics providers are able to resolve core integration issues that impact on-time performance, process automation and customer service,” Pease said. “Increasing process automation and system compatibility illustrate two key opportunities for logistics providers looking to outperform the competition and thrive in today’s tough economic environment.”

Utilizing ergonomically designed powered carts and tugs to replace the manual transport of materials and products is one way logistics companies can increase automation and improve production efficiency. With the logistics industry facing a shortage of workers, ergonomic material handling solutions allow each worker to efficiently accomplish a greater workload while dramatically decreasing potential risk of injury. Replacing expensive, high-maintenance, fuel-guzzling forklifts and gas/diesel-powered equipment, with less costly, more maneuverable, electric-powered carts and tugs can result in a considerable savings in high fuel costs. These smaller, more maneuverable carts also provide more versatile solutions to material handling problems. For more information on ergonomic solutions to material handling problems, visit the DJ Products website.

Supply Chain Digest Announces Fall Workshops

Supply Chain Digest is pulling out a heavy-hitter to headline its annual fall workshop on improving distribution center and warehouse management and performance. Ken Miesemer, Senior Consultant at St. Onge and former Director of Distribution and International Logistics for Hershey Foods, will lead two fall workshops being sponsored by the industry magazine. “Best Practices in Distribution Center Design, Operations and Management” will be presented in Philadelphia on October 21-22 and in Atlanta on October 28-29.

Author of the book Start-Up of a World Class DC, Miesemer said, “These workshops use outstanding materials that have been extremely well received by logistic professionals, and deliver concepts and insight that aren’t just theory but which have been proven in real-world distribution environments.”

Billed as “hands-on, practical training sessions,” Supply Chain Digest’s popular Professional Education Series workshops encourage interaction between instructors and distribution, warehousing and logistics professionals. In addition to Miesemer, Supply Chain Digest editor Dan Gilmore will review supply chain execution software systems. Course materials include distribution analysis and decision-making tools and templates that attendees will be able to implement in their own operations. The discussion and provision of practical action plans is a hallmark of Supply Chain Digest workshops.

The workshops will focus on the implementation of best practices to improve labor productivity, operations efficiency and inventory accuracy using proven techniques and technology. Course highlights include: building and material handling equipment design, testing design through automation, organizing to minimize bottlenecks, workforce performance management, fostering a culture of continuous development and improvement, differentiating solutions, redefining bid specifications, controlling risk driven margin expectations, and much more.

“Best Practices in Distribution Center Design, Operations and Management” workshop details:

October 21-22 at Penn State Great Valley Conference Center in Malvern, PA just outside of Philadelphia
October 28-29 at Georgia Tech Conference Center in Atlanta, GA

Click here for a complete course outline and hotel and registration information.

What New Material Handling Innovations Were Showcased at ProMat in Chicago?

As anticipated, ProMat 2015 unveiled a wide variety of exciting new tools and solutions for warehouse efficiency. Chicago hosted the annual convention recently, and leaders in the material handling industry learned about innovative new products and advances in the field that are bringing great value to businesses — in the future and right now.

Highlights from ProMat 2015

We are particular excited about the products that boost efficiency by making it easier to store, move, and track inventory. At the Modula booth, for instance, the shelving and storage innovator showed off a new vertical storage solution. The new Modula VLM makes it easier to make use of square footage by maximizing vertical space. Controlled by computer and integrated with inventory management, the VLM makes it easy to pick items ranging from tiny and lightweight parts to large and heavy materials that weigh over a ton.

Our own warehouse mover solves the other half of the equation: pushing and pulling large, heavy carts around the facility. Workers slow down and face back, shoulder, and leg injuries from manually pushing wheeled carts. The warehouse mover speeds up material handling in two ways: automating cart movement, and keeping employees healthy and energized to get more done.

Other exciting highlights from ProMat 2015 included the Nuvera fuel cell battery from Yale and powerful fleet management software from Raymond. Overall, ProMat featured a wide variety of tools to improve efficiency and productivity in warehousing and material handling.

For more information about innovative new tools to speed up material handling at your facility, check out the warehouse mover and other industrial cart movers from DJProducts.com.

History and Popular Trivia of the Forklift

The forklift, as we know it, began life as a powered winch. It was used to hoist heavy objects, and used electrical motors to get the job done. They were compact but specialized, with pulleys and chains for lifting heavy objects. World War II saw the widespread uses of these hoists, as they were mainly employed to lift up bombs for transportation. That’s a job that certainly calls for hazard pay!

In 1920, the first hydraulic lifting system was invented, and this was melded to a couple of forks. These huge trucks were the direct forerunner of the forklifts that we see today, and when pallets became standardized in the late 30’s, so too did the forks to lift them. But they were big and bulky, and they needed a lot of space to work.

When electric motors and hydraulics finally came together in the mid 40’s, the first real forklift was born. These vehicles were relatively small and compact, yet they could lift very heavy loads.

Here is some trivia.

Forklift batteries originally only lasted 8 hours on a full charge, which is how long an average working shift lasts.

Forklifts account for only 1% of all accidents in a commercial setting.

A forklift was once used to steal an ATM.

A modern forklift called a “Sidewinder” is the only forklift that can travel in any direction, even when it is carrying a load.

If you want more information about what a forklift or other industrial cart movers, like trailer movers, small aircraft tuggers and dumpster movers, among others, can do for you, please contact DJ Products.

Looking to Save Money in Your Warehouse? Look for New Packaging Solutions

The shift toward dimensional weight shipping rates has triggered a cascade of changes on warehouse management. Many warehouses are sidestepping the higher rates by using polybags or Tyvek mailers instead of boxes.

Along with the potential savings, soft bags present a new set of challenges compared to the familiar and reliable process of handling rectangular boxes.

As Alexander Communications points out, polybags require new technology for picking and scanning. The ultimate cost savings, however, should drive warehouse managers to analyze whether products can be mailed in polybags and how to make the process effective.

Key considerations for using packaging solutions to circumvent dimensional weight shipping charges:

Scanning and sorting solutions must be able to handle irregular shapes.

Material handling can become more efficient because more items can fit in a cart and be transported with motorized warehouse tugs.

Warehouses can often find ways to ship some, if not all, products in bags. Using both bags and boxes does not necessarily present an insurmountable challenge.

Customers can be charged dynamic rates based on actual shipping — or flat rates that protect your margins when boxes must be used.

Be sure to not overlook the changes that polybag shipping will have on material handling inside the warehouse. Instead of a pallet with several large boxes, you may have a cart weighted down with many more products in polybags. Warehouse tugs automate this movement to streamline the process and protect workers from injuries.

When cost savings are on the line, the boost in productivity from warehouse tugs can maximize the benefits of new packaging solutions. Visit DJProducts.com for more info about industrial cart movers.

How to Attract and Keep Young Talented Workers to Your DOD Contracting Business

One of the most overlooked warehouse management tips is attracting and keeping young talented workers in a department of defense contractor scenario. This may even seem like a non-issue because the standard has always been to give someone a job, give them a fair rate of pay, and they would then stay there until they retired.

But that mindset no longer works for a modern job force under 30 years of age. You have to learn and understand the nature of this modern workforce in order to keep them on the job for the long haul.

Family Friendly

Although you are employing one single person, the family comes along for the ride. Competitive businesses allow such things as paternity leave, flexible schedules and telecommuting, to name a few. Making your business family friendly makes for long term employment.

Growth Within

In this case, one of the most important warehouse management tips is to give the opportunity for growth within the company. These younger employees are more apt to enroll in higher education, gain knowledge and experience, and move on to another job if a growth opportunity does not present itself within a reasonable time.

Perks

In this day of modern communication, which is nearly constant, get Wi-Fi for computer access to allow these younger employees to stay connected during lunch hour and breaks.

Many employees may also have kids that need daycare or nannies, and that can be a valuable perk if offered on-site.

For more information on this or products that will aid your DOD warehouse, contact DJ Products, makers of trailer movers, tuggers, dumpster movers and aircraft tugs.

Day: June 14, 2016