Tag: Warehousing

A Little Goes a Long Way

When it comes to performing any job, it’s imperative that workers have both the “know how” and the proper equipment to accurately perform every task they encounter.  An employee attempting to figure out how to use a piece of equipment as he goes can result in plenty of wasted time and even put people at risk of injury.

Upgrading every piece of computer and material handling equipment at once could bring about too much of an expense for some distribution centers to bear, but taking small steps to ensure that you have all of the equipment necessary and that all of your employees know how to use it is a big step towards optimal efficiency. 

Having only one big, bulky forklift that is constantly breaking down doesn’t make much sense when you receive and ship out dozens of pallets worth of material per shift.  In the long run, you could save money on operating costs and move more freight if you scrapped the outdated forklift in favor of two smaller battery powered lifts.  Battery powered lifts from DJ Products are designed to be safe and easy for any employee to learn how to operate, which could mean a lot less waiting and a lot more working.

These battery powered lifts and carts from DJ Products can also last an entire shift on a single charge, so there is no time wasted changing fuel tanks and fewer moving parts means that there is less chance for equipment breakdown and a smaller budget required for equipment maintenance.

Streamlining or optimizing can sound like overwhelming processes to undertake, especially for a business trying to survive during these tough economic times, but properly training your employees and providing them with the right equipment may be all that needs to be done to make your operation as efficient as possible.

The Future Is Now!

If you have kids, you’ve probably seen trailers for the new Disney-Pixar animated film WALL-E. Robots like WALL-E and his cohorts represent the wave of the future in material handling, though let’s hope they get the kinks worked out before they start installation. Can you imagine the chaos if a bunch of inept robots was allowed to run amuck on your plant floor? Life, after all, is not a movie. The hero almost never arrives to save the day in the final seconds of a plant emergency!

Robot prototypes that allow us to glimpse and plan for the future of material handling are already on the market. British tech firm RTS Flexible Solutions has introduced a 3-D vision-based robot automation system that can grip complex shapes and profiles, pick at variable heights and even perform some inspection and defect rejection actions.

“Advances in technology mean we can deliver applications which have been difficult for conventional 2D technology,” commented RTS managing director David Bradford. While 2D vision-guided robotic automaton works on grayscale, color or line-scanning vision systems, the new 3D system can process on X, Y and Z coordinates. For the first time this allows a robotic application to accurately gauge height, depth and surface contours, opening new possibilities for material management. 

It will be a while before robotic applications can effectively perform many material handling functions, but that day can already be glimpsed on the horizon. Computer software and management skills are more apt to define material handling workers of the future. It’s going to be a whole new ball game!

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.”

Safety Breeds Productivity

Too many warehouses and material handling companies view safety as secondary in order of importance compared to customer service – but a clean, safe and clutter free workplace can have a huge effect on productivity.

Organization is key in being able to deliver optimal customer service as orders can be pulled, stationed, packed and shipped much more quickly and efficiently in an environment that is clutter free and safe.  There is also a much lower chance of injury in an environment that is organized, properly equipped and well designed.

Warehouse and plant managers shouldn’t wait for fire or safety inspection time to roll around to get their operations organized and clean – the possibility for greatly increased productivity and, in turn, an increase in the bottom line along with a loyal customer base are readily available for business that can provide lightning quick and pin point accurate service.

Employees who work in atmospheres where the equipment is outdated and unreliable are more likely to have to perform the brunt of their jobs manually; this can lead to oversights and errors that may affect the accuracy of orders and of your inventory.  It can also result in material being left in areas that weren’t necessarily meant for storage, potentially leading to accidents or injuries.

Upgrading your material handling equipment to battery powered carts that are quiet, ergonomic and long lasting will allow your employees to work at a faster pace without having to worry about resorting to manual handling when the equipment fails.  Nothing hurts moral and performance worse than equipment failure during the picking or stocking of a large order when the pressure is on to perform.

Electric Carts from DJ Products have the power to last for an entire, fast paced shift of shipping/receiving without any worry about failure.  This means that your employees can fully receive stock orders and put them away, or pull and stage large orders without interruption – with the right equipment; your warehouse will be clean, organized and operating at the highest possible level of efficiency.

Make Power Moves with Power Pullers

When people talk about someone having “pull” in an informal sense, they mean that the person has the power and influence to attract or draw resources towards them. People who have “pull” are able to exert this influence effortlessly.

In contrast, being able to have “pull” a warehouse or hospital setting often requires a lot of effort. And there are times when that effort can cause injury. A DJ Products CartCaddyLite Shorty power puller is a battery powered tug designed with enough power to maneuver carts through confined environments where tight maneuverability is of a huge concern. You can use it to help transport dollies, hand trucks, linen carts, hospital carts, maintenance carts and even hospital beds. Even though these carts are typically less than 1500 lbs. and usually maneuvered manually, pulling them can cause considerable strain. If our battery power puller is used, risks of fatigue and injury to valuable workers can be reduced.

With the CartCaddyLite Shorty, there is no need to jackknife or manually turn the front of your cart because once you attach the arm to your carts or equipment, the puller can pivot a full 180 degrees under the arm.

Power Pullers and Power Movers from DJ Products give employees the “pull” they need to get their work done without straining muscles and risking injury. And giving your employees the right tools can boost morale in a way that gives you more “pull” as well.

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.

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.

Tips for Ramping Up Warehouse Efficiency

The economy is forcing everyone to tighten up operations. Efficiency is today’s business byword. In a timely article posted on Supply Demand Chain, TriFactor systems engineer Greg Tuohy offered provocative tips to ramp up warehouse efficiency by improving material handling processes in distribution centers.

  1. Know where you’re at. Before you can decide where to make improvements, you have to know where you are, says Tuohy. Review operational data and break it down so you can see where your money goes and relationships between processes. Start with the big picture, but break it down to figure the cost of each element in the process. This will show you where you’re getting the best value for your dollar and where you need to tighten up your operation.
  2. Define customer service. Tuohy recommends defining your commitment to customers as narrowly as possible to allow more accurate measurement of success or failure. Defining what constitutes achievement of a perfect order, including labeling, delivery time, damage and documentation, also defines employee goals and customer expectations. Aim for realistic and achievable results that will give you a competitive edge.
  3. Touch it once. Each time an item is touched invites human error. Track the number of times an item is touched from the time the order is received until it ships out of your facility. Work to eliminate as many steps in the process as possible.
  4. Look up. When you need to expand operations, expand upward into unused overhead space instead of laterally. Elevating operations makes more efficient use of available space, allowing you to extend the useful life of your facility.
  5. Map SKUs. Gather data on SKUs in inventory, says Tuohy. Carefully map each SKU for shape, weight and velocity of use. Knowing how fast items move from demand to use allows you to slot your facility for maximum efficiency. “The data also allow you to take advantage of the cubing features of most warehouse management systems in order to calculate the appropriate-sized carton to use for a respective order,” says Tuohy, thus reducing carton and packing filler expenses.

Next time: More ways to ramp up warehouse efficiency

Bigger isn’t always Better

Staying operational in rough economic waters sometimes means having to make some big changes – one of those changes that some distribution centers are making is to open more locations.  Opening more locations doesn’t really sound as though it would be a good way to cut costs and increase the bottom line; but if those new locations are smaller and better equipped to serve the customer – it can certainly be a way to turn more of a profit.

Many companies are looking to eliminate extremely large facilities that carry high overheads in terms of rent and utilities in favor if smaller, lower cost buildings that are able to deliver service at faster speeds.  One large centralized location that is capable of carrying plenty of inventory does have some advantages, but multiple locations that are strategically placed can have many more benefits when it comes to provide quick and accurate service to customers.

It can be quite a bit easier to keep track of product in a smaller and well organized building, everything needs to be processed and put away upon arrival because your employees won’t have the extra space for product to sit around on pallets.  With your entire inventory put exactly where it needs to be up receipt, there won’t be any room for error – inventories will be easier to control and orders won’t be lost due to misplaced product.

Bigger isn’t always better in terms of equipment either and when distribution centers shrink down in size to become faster and more effective, they often need their material handling equipment to do the exact same thing.  In a small and fast pace environment, you can’t afford to have over-sized, unreliable and outdated equipment – you need carts and lifts like those offered by DJ Products; equipment that is small, easy to use and that will last an entire shift (or more) on a single charge with no fear of failure.

Your employees will be moving at lightning speeds in order to process customer orders; they’ll need safe, effective and reliable equipment to help them perform their job properly – equipment like the carts and lifts offered by DJ Products.

Ergonomics and Grocery Warehousing

The Occupational Safety and Health Administration (OSHA) has a special webpage where it outlines some of the ergonomic issues that face workers in grocery warehouses that highlights “Traditional Order Picking” as an area of ergonomic concern because this system “accounts for a large number of musculoskeletal disorders.”

In the Traditional Order Pick System, products arrive on pallets and are placed on slots that are stored vertically to make the most efficient use of space. OSHA points out that this system also makes efficient use of employee effort since the pallet is not moved around several times, but only gets lifted once and placed in its correct slot until it is time for the products to be removed to fulfill an order. Employees are also able to take “frequent micro-breaks” as the go from one slot to the next.

However, since there is no perfect system, OSHA also points out the disadvantages of this process: workers are “exposed to a number of musculoskeletal stresses including heavy lifting, bending, reaching, twisting, etc.”

Perhaps you haven’t really examined the systems you have put in place at your warehouse, but if a number of employees have either complained of work-related strain or filed for workers compensation because of injuries, it may be time to look at your processes.

Even if you are not able to rearrange your warehouse, change the way products are delivered, or alter the way orders are fulfilled, you can make certain that your employees have material handling solutions that can help minimize strain. DJ Products offers power pullers and industrial power movers that can help workers fulfill orders without undue strain.