Tag: Material Handling

Material Handling Solutions for Big Box Stores

With the current state of the economy, everyone is trying to do whatever they can in order to save some money.  That has many consumers buying in bulk at big box/outlet stores in an effort to spread their money out just a little bit more.

Outlet stores operate like a cross between a warehouse and a retail establishment, which poses some differences and potential problems with actually getting the material from receiving to the sales floor where customers have the opportunity to purchase.

It’s absolutely crucial for these types of environments to have safe and reliable equipment in order to meet the customer’s needs.  The employees need to be able to move large quantities of product literally among the customer base during business hours, so safety is a huge concern.  No outlet store can operate successfully with loud and difficult to operate equipment – all material handling equipment needs to be easy to operate and not overly disruptive to the consumer experience.

Once the safety of the employees and customers has been taken care of, reliability is the second biggest concern.  Even the slightest failure of material handling equipment in a big outlet store could spell disaster as much of the material moves directly from receiving to the sales floor in bulk loads.  If the equipment is not functioning for even a short period of time, there could be dozens and dozens of lost sales and potentially lost customers.

Properly trained, reliable employees and reliable equipment are two of the biggest keys to the success of big box and outlet stores.  Reliable equipment ensures that the material hits the sales floor in a timely manner and is available for sale when the customers are looking for it.

Highlighting the Yard Dog

There was a time when there were only two options for moving OTR trailers, tanks and other heavy equipment. You could use boxy, light duty forklifts and cumbersome yard dogs or pay a hefty price for better quality walk-behind movers. Today our Powered Trailer Dolly combines performance and value to solve all your heavy-material handling issues.

This multi-purpose unit works for horse trailers, boats, RVs and any other equipment trailers that require lifting on one end before maneuvering. Its 36-volt motor and hydraulic lift kit enable it to handle tongue weights between 5,000 and 15,000 pounds.

Operator safety is a key factor in the designer of our trailer dolly. The ergonomically sound variable speed twist grip prevents carpal tunnel and there’s a easily accessible safety stop switch in case of emergency. Reducing the effort needed for your employees to transport heavy trailers results in fewer injuries and less time missed on the job. There’s no special training needed to operate the dolly, meaning any of your associates can easily work with them.

Major trailer manufacturers such as Wabash National Corporation and Great Dane have successfully incorporated our trailer dolly into their operations for greater efficiency and improved flexibility. With an assortment of optional features like king pin attachments for fifth-wheel trailers, it can be modified and customized to suit all your needs.

The Powered Trailer Dolly is just one solution in the comprehensive line of material handlers from DJ Products. They suit applications from hospitals and hotels to automobiles and aircraft. Our Sales Engineers can answer all your questions at 800.686.2651.

Ergonomic Plan Can Help Attract and Retain Workers

This week we’ve been talking about the growing worker crisis that faces the material handling, manufacturing, warehousing, logistics and related industries (see our Nov. 3 post). By 2010, American industry will face a 50% shortfall in its material handling workforce. Attracting workers to material industry jobs is one of the biggest challenges of our industry (see our Nov. 5 post), particularly with worldwide growth in our industry expected to remain robust over the next several decades. Developing and instituting a comprehensive ergonomic plan in your company is an excellent way to attract new workers and retain your current workforce.

Ergonomics is the science of designing equipment and planning work tasks with the goal of eliminating workers’ risk of musculoskeletal injury. Equipment and tasks are designed around the capabilities of workers and seek to make it possible for workers to perform tasks with a minimum of physical strain and effort. A comprehensive ergonomic plan combines the use of ergonomically-designed equipment with ergonomically-planned task procedures to make it possible for workers to perform tasks more efficiently with a minimum of potential injury-causing motions.

Any time a worker has to bend, stretch, reach, push, pull or lift, he runs the risk of serious musculoskeletal injury. These injuries cost U.S. businesses more than $150 billion a year. More than 13 million American workers suffer non-fatal injuries each year, and 6,500 people die from workplace injuries. Workers’ compensation costs U.S. businesses $60 billion annually, according to the U.S. Department of Labor. More than 25% of those claims are for back injuries caused by repetitive lifting, pulling, pushing and straining. Back injuries alone affect more than 1.75 million workers a year, costing American businesses more than $12 million in lost workdays.

When you implement a comprehensive ergonomic plan, you send an immediate message to your employees that you respect their contribution to your business and value their health and safety. That, in turn, engenders worker appreciation and loyalty. The ability to offer a safe, ergonomic work environment is a powerful inducement in attracting and retaining your workforce.

DJ Products is an industry leader in the manufacture of ergonomically-designed electric and motorized cart pushers. Our equipment is less costly, smaller and more maneuverable than traditional equipment used to move carts and equipment. Ergonomically-designed equipment increases worker efficiency, thus improving production efficiency. In most situations where ergonomic equipment is introduced, businesses recoup purchase costs within the first year in medical, insurance, workers’ compensation and lost work-days savings alone. An investment in ergonomic equipment is a win-win situation for both businesses and their workers. DJ Products’ ergonomic specialists can help you assess your equipment needs and explore custom applications to benefit your business and your workers.

U.S. Manufacturers Turn to ‘Insourcing’ to Save Money

Insourcing is the new buzzword in U.S. manufacturing circles. U.S. economic woes are causing many manufacturers to replace outsourcing with insourcing, an unexpected boon for American workers. The declining value of the dollar against foreign currencies, skyrocketing transportation costs caused by high fuel prices, and decreasing export demand resulting from the global economic downturn are making it more cost efficient for U.S. manufacturers to produce their products at home.

The same economic forces that sent U.S. jobs overseas are now bringing them home. Manufacturing costs in Alabama are currently running 3% below those in China, causing companies like Exxel Outdoors, Inc., which makes sleeping bags for Wal-Mart and other customers, to execute an “about face” on its production priorities. Since the Wall Street tumble, the company has hired more workers, added new equipment and beefed-up production at its Haleyville, Alabama plant, while cutting production at a joint venture in Shanghai. In 2007, 60% of Exxel’s bags were made in Shanghai. This year, the company will make more product at home than abroad and expects to produce 90% of their product at their Alabama facility by 2010.

Exxel founder and CEO Harry Kazazian is predicting a 20% increase in company revenue this year to $42 million. He credits insourcing as a major factor in his company’s success during a tight economy. Since 2005, he has seen the yuan appreciate 17% against the dollar, pushing up Chinese wages, material costs and freight costs. Kazazian says moving production from Shanghai back to Exxel’s Alabama plant just made financial sense.

“Labor is China’s advantage and our weakest link,” he said. “But they can’t compete with me on my just-in-time” production cycle. Exxel can deliver a sleeping bag from its Alabama facility within three days where shipping from China can take two months.

According to government statistics, U.S. manufacturing is contracting at the fastest rate since 2001, the last time America dipped into a recession. As countries around the globe struggle with the growing financial crisis, there has been a marked decrease in export demand. Without demand for the prodigious output that originally spurred outsourcing over the last decade, producing goods in the U.S. is becoming increasingly cost efficient. Smart companies are re-evaluating their outsourcing policies and making the switch to insourcing.

Obama’s Mandate to Transform America

“The deepening recession creates the opportunity for federal intervention and government experimentation on a scale unseen since the New Deal,” wrote Charles Krauthammer in a column for the Washington Post Writers Group that was widely published last month. Krauthammer is one of many Beltway watchers who have been predicting “a domestic transformation as grand as Franklin D. Roosevelt’s” once President-elect Obama takes the oath of office barely a week and a half from now. Krauthammer believes that Obama’s statement, “This painful crisis also provides us with an opportunity to transform our economy to improve the lives of ordinary people,” presages what will become the key thrust of the new president’s administration: the transformation of America from the ground up.

It’s hard to argue with Krauthammer’s view, particularly given the details about the President-elect’s economic stimulus plan and jobs initiative that are beginning to trickle into the press. As Krauthammer points out, the current situation is a community organizer’s dream and that’s always been Obama’s self view. He sees himself as a world changer but it’s his own world he most wants to change. He’s got Hillary Clinton and Robert Gates on board to keep the dogs of war at bay so he can focus his energies on rebuilding America.

The economic meltdown and jobs crisis have given Obama the public mandate to foment massive changes in governmental policy. People are clamoring for help and looking to Obama to provide it. A definitive win in November and the healthy Democratic majorities that rode into the House and Senate on Obama’s coattails gave him the political mandate and clout to drive new policies through Congress. The massive bailout funds already approved, with another huge chunk of money on the way, put at Obama’s disposal what Krauthammer calls “the greatest pot of money in galactic history.” Combined, current social, economic and political forces would seem to give Obama almost unlimited power to effect change.

That change is certain to increase regulation, government oversight and red tape. Bush administration regulations that critics say weakened the EPA and OSHA at the expense of environmental responsibility and worker safety are expected to be rescinded by Obama’s team in favor of measures that place the burden of responsibility and expense of accountability back on the doorsteps of manufacturers and American business owners.

Next time: Rolling with the punches; taking a proactive approach to coming change.

CartCaddyHD Chain Drive Cart Mover Increases Productivity

When companies purchase material handling equipment they usually consider the product and where and how it’s going to be moved. What they leave out of the equation is people. But as Bob Trebilcock reminds us in a March 24, 2009 posting on Modern Materials Handling online, it’s people who move products and supplies from point to point. Neglecting to consider the impact of workers on production will invalidate your productivity assessments.Trebilcock mentions programs some companies have implemented to improve worker morale and health that were showcased at the recent annual meeting of the Conveyor Equipment Manufacturers Association. He talks about one manufacturer’s installation of a company cafeteria for worker use to cut down on driving time during lunch breaks and to provide workers easy access to nutritious food. He mentions a firm that opened an onsite medical clinic and pharmacy to improve employee health, conduct medical screenings and reduce medical costs to its self-insured health plan.What surprised us here at DJ Products is that Trebilcock failed to mention the health, cost and productivity benefits of using ergonomically-designed material handling equipment such as the CartCaddyHD Chain Drive cart mover. Moving to ergonomic material handling equipment has been proven to drastically reduce on-the-job musculoskeletal injuries, improve worker morale and significantly increase productivity. Equipment costs are generally recouped within the first year, but savings in medical, health insurance, disability and workers’ compensation costs continue, as do savings from increased productivity. If a company is concerned about its workers’ health and safety, a move to a cart mover should head the list of improvements to be made.A leader in the design and manufacture of ergonomic material handling equipment, DJ Products produces a wide variety of cart movers and battery-powered cart movers for every application. From heavy industrial/manufacturing and assembly line settings to the busy, narrow corridors of hospitals and hotels, DJ Products’ ergonomic material handling equipment is improving workers’ health and safety and increasing their productivity across America.DJ Products’ designs its cart movers to take the strain of labor off the backs (and legs and arms and shoulders) of workers and put it where it belongs, on the material handling equipment they are using. Workers avoid the aches and pains that can make them less productive. Ergonomic equipment is less tiring to operate, keeping workers alert and productive for the entire length of their shift. Ergonomic equipment is easier to operate, allowing workers to complete each assignment more quickly, increasing shift productivity.If you really want to do something that will benefit your workers and increase productivity, make the switch to a cart mover. Visit the DJ Products website and let one of our ergonomic equipment specialists tell you how.

Downsizing without Alienating Customers

In this economy, where it’s been exceedingly tough to generate more income due to the fact that fewer individuals and businesses are spending quite as freely as they were once capable,  reducing overhead has been the easiest way for warehousing and logistics companies to maintain profitability.  Usually the two largest areas of expense lay in employees and in rent, and since it’s impossible to run a material handling business without employees, many companies are doing what they can to reduce the amount of money they spend per month on rent.

The biggest problem with shrinking your operating space is the risk of not being able to fully serve your customers – the only way reducing overhead works to maintain profitability is if it doesn’t cause the loss of some of your sales.  This means that a warehousing or distribution company needs to carry as much inventory and maintain the very same fluidity of operation, but they need to do so in a smaller space.

Though this may not sound very realistic, with the right employees and the right equipment it is very possible.  Lifts and carts from DJ Products are consistently reliable and easy to maneuver in even the tightest of spaces.  These quiet and ergonomic carts are among the safest in the business for warehousing employees to operate and they allow just one user to move a multitude of smaller items or a few heavy items without enlisting anyone’s help.

A few well trained employees who have access to the best material handling equipment can perform a task much more efficiently than a full crew trying to operate outdated equipment that could be prone to failure.  When an incoming shipment can be received and appropriately stationed to go into stock or to go out for an order, then either put away or shipped more quickly and efficiently – a warehouse is able to successfully operate in a potentially much smaller environment.

Ergonomics Investment Adds to Healthy Bottom Line

Every dollar invested in an ergonomics program results in a savings of $4. That’s the astounding finding of a recent study on the cost effectiveness of implementing ergonomics programs in U.S. manufacturing and business settings.

In the past, many companies didn’t initiate ergonomic programs until forced to do so in response to workers’ compensation claims. The expense associated with claims coupled with the responsibility to eliminate hazardous work conditions forced companies to implement solutions to address ergonomics issues. But acting after the fact only prolongs the agony, pointed out Mike Kind, writing for the New Hampshire Business Review. “As claims are filed, an organization’s workers’ compensation premium increases immediately upon renewal. It then takes a three-year history of reductions in claims for the rate to drop.”

Proactively implementing an ergonomics program may not eliminate every future workplace injury, but the use of ergonomically-designed equipment and the introduction of ergonomic practices has been shown time and again to significantly reduce workplace injuries and their associated costs. In most cases, the cost of ergonomics equipment is recouped within the first year.

As an example, Kind cited a highly computerized operation in which more than half of the employees reported musculoskeletal disorders during their first year on the job. Implementation of an aggressive ergonomics program, including new equipment, procedures and training, resulted in an overall 50% decrease in worker complaints.

Proactive implementation of ergonomics initiatives impacts your bottom line immediately and positively.  “In one client research study, it was determined that for every dollar invested in an ergonomics program, $4 in cost savings were achieved,” Kind said. Reduction of worker injury results in significant savings in direct medical costs, insurance and workers’ compensation premiums. Lost work-hours due to doctors’ appointments, physical therapy sessions, sick days and absenteeism decrease. As employee safety and well-being improve, workplace morale increases, bringing with it a healthy work environment, increased productivity and improved customer service.

Creating a successful ergonomics program hinges on three important elements, Kind said:

  • Support of top management and inclusion in the corporate culture 
  • Establish goals and measure results
  • Provide effective education, training and leadership

Next time: Tips for creating a successful ergonomics program

Plenty of Jobs Available in Material Handling Fields

With the economy down and unemployment up, jobs are a hot topic this election. As industry starts to feel the economic pinch, plants are closing, workers are being laid off and some companies are facing bankruptcy. But there are jobs aplenty in the material handling industry and the associated industries of logistics, fulfillment and warehousing.

There’s a severe shortage of qualified industrial workers in America, particularly in material handling fields, that holds promise for job-seekers. The material handling industry is expected to be “50% short in terms of employees needed by 2010,” said Virginia Wheeler, executive director of the Material Handling Industry of America’s (MHIA) Education Foundation. The growing worker shortfall guarantees job security well into the next decade for people going into material handling jobs in warehouses, fulfillment centers, logistics operations, and factories.

“Our industry is begging for people,” said Dan Quinn, MHIA VP for education. He feels America’s high schools are undercutting the value of the trade jobs that built and continue to build America. “A lot of schools measure themselves on the percentage of students who go on to college,” Quinn criticized. “Schools should embrace the concept that non-college-bound students are still valuable contributors to the economy and society.”

The reality is that many high school students are not interested in pursuing a college education for a wide variety of reasons. Many simply prefer hands-on, physical work to sitting at a desk. Many are anxious to get out on their own and lack the interest in four more years of schooling. Many do not have the financial resources to consider college but must provide for themselves immediately after high school graduation. As the recession deepens, finances are expected to play an increasing role in education/work decisions. Some high school juniors and seniors, like Alaska Governor Sarah Palin’s future son-in-law, have already been forced to drop out of school to help support their families. Some employers are offering their employees the opportunity to complete their high school education through GED programs.

It’s unfortunate that many high school guidance counselors are so focused on college that they ignore the positive opportunities available in material handling industries. Raising awareness of job opportunities is one of the primary challenges facing the material handling industry, said Alan Howie, author of Fundamentals of Warehousing and Distribution. “. . . the essential problem is we have to get the message out there that . . . work in the material handling industry is much more than a manual labor job. It’s a career in a high-tech industry. Our challenge is to build awareness of all of this in the schools and colleges.”

Free CartCaddy Demo Program Lets You Try Before You Buy

If you’re a businessman, you know that marketing and sales can get a customer in the door and make that first sale, but it’s superior customer service that keeps customers coming back. The management and staff of DJ Products are dedicated to providing our customers with superior service. If you have a material handling problem, our trained sales engineers can help you find a cost-effective, ergonomic solution that will improve production efficiency, benefit employee health and safety and improve your bottom line.

That’s a tall order for one of our compact, fuel-efficient, highly-maneuverable CartCaddies, but we know our equipment. We’re so certain of our product, we offer a free demo trial program. Try before you buy! Contact us and one of our sales engineers will make arrangements for you to receive and utilize a CartCaddy cart pusher at your facility before you buy. Put our ergonomically-designed, easy to maneuver, extremely versatile CartCaddy cart movers to the test in your own environment before you decide to order. It’s a good way for you to get to know us and experience first-hand the superior customer service that keeps our customers coming back.

A typical response from our demo program is this comment from C.F. at Admiral Beverage Corp.: “Tried it, all is well! Just send the invoice for payment.”

Here’s what some of our other customers have to say about DJ Products’ innovative CartCaddy carts, tugs and movers and our superior customer service program:

“Very impressed with the unit and love it!” said M.W. of Mark Webber, noting that the unit shipped sooner than expected.

“The CCShorty is working great. We haven’t had any problems with it. I will share this with other Weyco. Thanks for checking on us,” said J.G. of Weyerhaeuser, pleased with our follow-through customer service.

“The CartCaddy 5WP is working very well. The service you provide is great and it will be a pleasure to do future business with you,” said S. F. of Weyerhaeuser.

“Easy to operate, lots of power! Just like you said!” raved S.P. of Advanced Barrier Extrusions.

“First try worked flawlessly; all folks like it. Very maneuverable; talking about buying second unit,” noted a pleased R.R. at Aerospace.

“You did a great job adapting it to our containers,” said B.W. of Air Products, noting our ability to engineer and build to order.

“They got all five units. The one extra unit was for their gift shop and they LOVE it. They are very pleased with all the units; made their job so much easier,” said L.S. of the Arkansas Children’s Hospital. The hospital’s L.F. added, “Very pleased with your service and assistance … been a pleasure working with you.”

“Folks surprised at how fast it goes,” said A.P. of Airforce Research. “Slicker than they thought!!”

“The unit they have now; they want another one! Sending over PO# for two units,” said A.B. and Add Vantage.