Modern Materials Handling - February 2011

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tough environments and tough economic times – SK2000 from Steel King. • More impact ... 700 exhibits and include a comphrehensive educational conference. The event, held at .... Industry Survey, the timing of this year's show should certainly .... of Supply Chain Security in a Risk-Based World,” Ridge will examine the ...
PRODUCTIVITY SOLUTIONS FOR DISTRIBUTION, WAREHOUSING AND MANUFACTURING

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® February 2011

SPECIAL ISSUE

CHICAGO, 2011

Putting productivity to work

SYSTEM REPORT

Simon & Schuster set a textbook example 42 SPECIAL REPORT

2011 conveyor survey 66 EQUIPMENT 101 SERIES

Rack basics 60





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FAS T FAC T

UP FRONT

Breaking news you should know

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.

PECO pallets now available in Mexico PECO Pallet is now shipping its signature red wood block pallets to manufacturers and retailers 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 company’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 shipping into Mexico and also to pallets shipping back to the United States.

Psion drops “Teklogix” from name

RedPrairie grows by three

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 developments 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.

RedPrairie has RECENTLY added the expertise of three software companies to its portfolio. RedPrairie (www.redprairie.com) has acquired: • Shippers Commonwealth, a provider of software-as-a-service transportation management systems and collaborative transportation solutions; • SofTechnics, a provider of integrated retail enterprise solutions and inventory management solutions that has been serving customers for more than 20 years; and • Escalate Retail, a provider of all-channel commerce to specialty retailers, direct marketers and bigticket retailers.

Alabama Robotics Technology Park to educate in robotics, automation 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 industry need, which will provide college level courses on every aspect of robotics training, including robotics safety. Omron is the primary robotics safety provider for the project. “The vision of Alabama Governor Bob Riley, the RTP is a collaborative effort between the state of Alabama, Calhoun Community mmh.com

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 current 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.” Modern Mat eria l s Ha ndl ing / F

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Some things are

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PRODUCTIVITY SOLUTIONS FOR DISTRIBUTION, WAREHOUSING AND MANUFACTURING

COVER STORY PROMAT 2011 SHOW PREVIEW

22 Putting productivity to work ProMat 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.

FEATURES

60 Seconds with... George Prest

DEPARTMENTS & COLUMNS

SYSTEM REPORT

3/ Upfront

42 Simon & Schuster: A twice-told tale

7/ This month in Modern

A warehouse control system and new technology is the hero at Simon & Schuster’s New Jersey distribution center.

19/ Lift Truck Tips: Attachments

SPECIAL REPORT

77/ Focus On: Lift trucks

51 Productivity Achievement Awards Modern’s annual Productivity Achievement Awards honor companies that have made outstanding strides in improving operations through materials handling and related information systems.

40/ Supplement: Warehouse & DC 82/ 60 Seconds with...

NEWS 9/ ProMat 2011 ready for 30,000 attendees

PRODUCTIVITY SOLUTION

58 Lean and green pallets

14/ Behind Intermec’s acquisition of Vocollect

With a new presswood pallet, Lincoln Electric is not only meeting European export requirements and streamlining its pallet inventory, it’s reaping sustainability benefits.

15/ ISM’s January manufacturing data shows strong momentum to begin 2011

EQUIPMENT 101 SERIES: PALLET RACK

60 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. SPECIAL REPORT

66 Reader survey: Conveyor technology 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. mmh.com

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-qualified 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 offices. POSTMASTER: Send address changes to: Modern Materials Handling, PO Box 1496, Framingham MA 01701-1496. Reproduction 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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THIS MONTH IN

®

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Michael MichaelLevans Levans GGROUP DITORIAL IRECTOR ROUPEE DITORIALDD IRECTOR [email protected] [email protected] Bob BobTrebilcock Trebilcock EEXECUTIVE DITOR XECUTIVEEE DITOR [email protected] [email protected] Noël NoëlP.P.Bodenburg Bodenburg EEXECUTIVE DITOR XECUTIVEM MANAGING ANAGINGEE DITOR [email protected] [email protected] Lorie LorieKing KingRogers Rogers AASSOCIATE DITOR SSOCIATEEE DITOR [email protected] [email protected] Sara SaraPearson PearsonSpecter Specter EEDITOR ARGE DITORAT ATLL ARGE [email protected] [email protected] Roberto RobertoMichel Michel EEDITOR ARGE DITORAT ATLL ARGE [email protected] [email protected] Tom Jeff Andel Berman CGOLUMNIST ROUP NEWS EDITOR [email protected] [email protected] Jeff Berman Josh Bond GCROUP NEWS EDITOR ONTRIBUTING EDITOR [email protected] [email protected] Josh MikeBond Roach CCONTRIBUTING EDITOR REATIVE DIRECTOR [email protected] [email protected] Mike Roach Wendy DelCampo CAREATIVE DIRECTOR RT DIRECTOR [email protected] [email protected] Wendy Daniel DelCampo Guidera AIRT DIRECTOR LLUSTRATION [email protected] [email protected] Daniel Guidera Brian Ceraolo ILLUSTRATION GROUP PUBLISHER [email protected] [email protected] Brian Ceraolo GEDITORIAL ROUP PUBLISHER ADVISORY BOARD [email protected] Ron Giuntini EDITORIAL ADVISORY BOARD OEM PRODUCT-SERVICES INSTITUTE Ron Giuntini JohnPRODUCT Hill -SERVICES INSTITUTE OEM ESYNC TRANSHill YSTEMS John ESYNC Rider TSusan RANSYSTEMS RIDER & ASSOCIATES Susan Rider Ruehrdanz RKen IDER & ASSOCIATES DEMATIC Ken Ruehrdanz John Usher DDr. EMATIC UNIVERSITY OF LOUISVILLE Dr. John Usher AlanOFB.LOUISVILLE Will UCol. NIVERSITY 2D MARINE LOGISTICS GROUP Col. Alan B. Will Wood 2Brett D MARINE LOGISTICS GROUP TOYOTA MATERIAL HANDLING USA Brett Wood Media, LLC USA TPeerless OYOTA MATERIAL HANDLING A DIVISION OF EH PUBLISHING, INC. Peerless Media, LLC Kenneth Moyes APD IVISION OF EH PUBLISHING, INC. RESIDENT AND CEO EH PUBLISHING , INC. Kenneth Moyes PRESIDENT AND CEO Brian Ceraolo , INC. EH PUBLISHING PUBLISHER AND EXECUTIVE VICE PRESIDENT Brian Ceraolo EERLESS M EDIA, LLC PPUBLISHER AND EXECUTIVE VICE PRESIDENT PMAGAZINE EERLESS MEDIA, SUBSCRIPTIONS LLC Start, renew or update your FREE magazine subscription at MAGAZINE SUBSCRIPTIONS www.mmh.com/subscribe. Start, renew or update your FREE Contact customer service magazine subscription at at: Web: www.mmh.com/subscribe www.mmh.com/subscribe. Email: customer [email protected] Contact service at: Phone:www.mmh.com/subscribe 1-800-315-1578 Web: Mail: [email protected] Peerless Media Email: P.O. Box 1496 Phone: 1-800-315-1578 Framingham, Mail: Peerless Media MA 01701 P.O. Box 1496 eNEWSLETTER SUBSCRIPTIONS Framingham, MA 01701 Sign up or manage your FREE eNewsletter subscriptions at eNEWSLETTER SUBSCRIPTIONS www.mmh.com/enewsletters. Sign up or manage your FREE eNewsletter subscriptions at www.mmh.com/enewsletters.

The importance of being there

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o one is a bigger advocate for online education than I am. In fact, we’ve built a major portion of Modern’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 floor, 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 considerably more optimistic about the future than just a year ago. In fact, slightly more than one-half (51%) told us that they’re Member

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Member of

proceeding with needed/planned purchases this year; most significantly, 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 floor. In fact, MHIA says it’s anticipating 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 faceto-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 floor 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 find 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. Winner Jesse H. Neal Certificates of Merit for Journalistic Excellence

Official Publication of

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New Order Fulfillment Engine Elevates Warehouse Performance 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

To learn more about the Dematic Multishuttle visit ProMat booths 3603 & 3612 or www.dematic.us or call 1-877-725-7500.

Visit Us at Booths 3603 & 3612

Di@blog best of Modern’s blogs Company Briefings | Bob Trebilcock CHEP aims to build the better pallet www.mmh.com/blogs

TRADESHOWS

ProMat 2011 ready for 30,000 attendees INDUSTRY TRADESHOW AND EDUCATIONAL CONFERENCE WILL ALSO OFFER ACCESS TO AUTOMATE 2011. BY NOËL P. BODENBURG, EXECUTIVE MANAGING EDITOR

IT SEEMS AS IF the Material Handling Industry of America (MHIA, www.mhia.org), sponsor of ProMat 2011, had a premonition of this winter’s wrath when it moved the biannual industry event this year from snowy January to March in Chicago. ProMat, the materials handling industry’s premier trade show and educational conference, will be held at McCormick Place South from March 21 to 24, and officials are getting ready to welcome nearly 30,000 visitors. Attendees will find more than 700 exhibits, two keynotes, two educational tracks and 80 educational sessions spread over the four days. In addition, registered attendees not only gain full access to ProMat, but also free entry into Automate 2011, held across the hall in McCormick Place North. Like ProMat, Automate mmh.com

(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 associations 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 first time to help visitors maximize their travel time and budget. Because of the logical fit 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 audience for the robotics and materials handling industries are very compat-

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ProMat 2011 Facts Name 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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ible and, because there is little overlap in the memberships 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, officials decided to have not one, but two keynote addresses. The first runs Monday morning and features Tom Ridge, the first 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 GovernmentIndustry Collaboration and Technology Transfer for the Next Generation of Robotic Solutions,” will feature speakers from NASA and General Motors. The two organizations 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 affiliated 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 affiliated groups are hosting gatherings to give show visitors the chance to meet and learn more about topics specific 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 Renewable Energy Lab (NREL).

Education

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Beyond the 700 exhibits on the show floor, 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

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10:30 a.m. to 3:15 p.m. Topics range from best practices reviews to maintenance to metrics. “The on-floor seminars are presented by industry experts 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 sessions, 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 discussing “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 supply chain might look like in 2030.

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With 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 specific, 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 sustainability, 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 fight 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 flow 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 efficiency and flexibility, cut costs and speed time to market. Exhibits from industry, commerce and government will be showcased throughout the 300,000 square foot show floor.

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TECHNOLOGY

Behind Intermec’s acquisition of Vocollect WHAT HAPPENS WHEN you combine the No. 1 provider of voice recognition solutions with the No. 3 provider of automatic data capture solutions? That’s a question Intermec and Vocollect

will begin to answer over the coming months and years. Last month, Intermec announced that it has entered into a definitive agreement to acquire Vocollect for $190 million in cash.

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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 complete 2010 results just yet, but based on estimates, the combined companies 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 warehouse. He also believes there are real opportunities for voice to expand, both geographically into new territories 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 market. 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 technology that can be applied to more workflows 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 solution that integrates with other modes of data collection, said David Krebs, director of the mobile and wireless mmh.com

practice at VDC Research: “We think there a lot of greenfield opportunities for voice as we enter this emerging wave of multimodal applications that combine voice with other technologies.” Krebs added that he will be watching to see how Intermec’s ADC competitors respond. “The acquisition strengthens Intermec’s warehouse portfolio,” he said. “If they can integrate Vocollect into their portfolio, it will be interesting Voice may be evolving to see how Motorola, LXE from a point solution to and Psion respond. They all a larger, integrated data compete indirectly against collection solution. Vocollect and now they’ll be competing directly against Intermec as well.” For now, Vocollect solutions will be offered by Intermec; 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 computing. “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 2011 BUILDING ON THE SUCCESS of a solid 2010, the manufacturing sector is off to a promising start in 2011, according 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 monthover-month growth in the sector,” said Norbert J. Ore,

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CPSM, C.P.M., chair of the Institute for Supply Management Manufacturing Business Survey Committee, in a statement. “New orders and production continue to be strong, and employment rose above 60% for the first 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 Production at 63.5 was up 0.5%. Employment at 61.7 was up 2.8%. Inventories 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 consumer showed up for the holiday season,

“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

which helped tremendously,” said Ore. “The other thing that helped was the clarity that was achieved over the tax code. People hit January with expectations for a good year and continuing growth, and the general 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 inventory issue is one of the more difficult things to analyze during this economic 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 business as usual level.” With New Orders and Production

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both above 60, Ore said that the strength in manufacturing being carried into the first quarter—even if the other two months of the first quarter are not as strong as January—the first quarter and first 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 first quarter, which could carry the first half of the year. We have had a lift in confidence, but I think there is still a lack of confidence in the federal government in dealing

with deficits. 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 manufacturing cycles generally last from 70 to 110 months, and there is an expectation that with 18 months of manufacturing growth in the books, it is realistic to expect another 12 at this point through the end of 2011.

blog@way

Excerpts from executive editor Bob Trebilcock’s blog go to... www.mmh.com for complete posts Is a hybrid AGV in your future If 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 communications director. The hybrid AGV Egemin is touting, and will have on display at ProMat, is a vehicle with dual functionality: an off-theshelf 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 SCE You’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 approaching the supply chain execution market today, according to Karen Peterson, vice president of supply chain execution solution management for SAP... The next wave of supply chain innovation Venkat 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 triggered by compliance to government regulation,” says Rajaji. “Think about Y2K. Think about Sarbanes–Oxley” Rajaji is global product manager for Infor’s product lifecycle management division. The government regulation he’s eyeing this time is the recently passed Food Safety Modernization Act...

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lift truck TIPS

Handle with care Force control attachments aim to take the guesswork out of clamping. By Josh Bond, Contributing Editor

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tatistics 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 computing 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 Vandehey. 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 driver 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 motor 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 integrate with a warehouse management system to provide even more specific information about proper load handling—again without any reliance on the operator.

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When force control was implemented at one paper facility, the manager informed Vandehey that the difference was immediate. “After it was installed, he told me, ‘One day the operators 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 product 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 Josh Bond is a contributing editor to Modern and can be reached at [email protected]. Mod er n Mater ials Hand ling / F

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SUPPLY CHAIN INNOVATION STARTS AT PROMAT 2011 ®

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 efficiency and flexibility 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.

SOLUTIONS THAT MAKE THE SUPPLY CHAIN WORK ®

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ProMat 2011 Keynotes Monday, March 21 at 8:45-9:45 am Fortune Favors the Brave: The Net Gain of Supply Chain Security in a Risk-Based World Tom Ridge First Secretary of Homeland Security Terrorism, natural disasters, vendor issues, and geopolitical influences can put issues such as supply chain security, cross-border collaborations, and security investment at the forefront of every proactive business agenda. During this 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 pm The 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:

My aspirations: 20-somethings sound off on what makes them tick Kim Absil, Sears Holdings Josh Dennie, Optimax Justin Love, Schlumberger Craig Eckrenrode, Stevens Co. Inc. What are you worth and why? Mitch Mac Donald, DC Velocity Dave Blanchard, Material Handling & Logistics Keeping top talent as the economy recovers Dan Boos, Boos Consulting Services Wednesday, March 23 at 1:00-5:00 pm Sustainability, 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”

Steve Thomas

Top trends in industrial sustainability Gary Forger, Material Handling Industry of America How LEED certification cuts costs and improves efficiencies Michael G. Englehard, ProLogis Walmart’s plan for sustainable distribution Virginia Garbutt, Walmart Canada A look at the sustainable supply chain of 2030 Benoit Montreuil, Université Laval What you can do to green the supply chain Steve Thomas

How to capitalize on diversity in the workforce Dan Boos, Boos Consulting Services Dan Boos Preparing people for the workforce Kimberly Ellis, Virginia Tech Justin Love, Schlumberger Kathy DePiro, Greater Altoona Career & Tech Center Craig Eckenrode, Stevens Co. Inc. What a peer learning group can do for your career Josh Dennie, Optimax Bruce Peters, WCEOHQ Radio

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

SHOW PREVIEW Chicago March 21-24, 2011

PUTTING PRODUCTIVITY TO WORK

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Scalable staging buffer for goods-to-person picking operations Generating 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, palletizing, 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.

Voice-directed software with graphical management The latest version of Jennifer VoicePlus software for voice-directed warehouse operations has been released. Included is the Engage management 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 management 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, 724-9407000, www.lucasware.com. Booth 3879.

Tilt-tray, cross-belt sorters offered The 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 technologies are ideal for use in applications 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.

AGV converts to operator-guided forklift

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 hours Monday 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. mmh.com

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 guidance and navigation, advanced laser safety systems, graphical touchscreen monitor, Windows OS and wireless communications. Options include RFID readers, bar code scanners, 3D camera technology, robotic battery exchange, automatic battery charging, mechanism side-shift and single/double fork systems. Egemin, 616-393-0101, www.egeminusa.com. Booth 2347.

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AS/RS single-mast crane lifts 220 pounds to 39 feet

S H O W P RE V I E W

The Mustang Evo automated storage and retrieval system for mini-load use is a singlemast 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 specially 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 distribution 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, jetblack 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 allocations 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 install To 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 systems up to Windows 7. Multi-lingual technical support is offered. Features include the display of real-time statuses of stock levels, locations, productivity and shipments for increased warehouse performance, increased turnover ratios, optimized order preparation, improved online inventories, and reduced time needed for stock management. Interlake Mecalux, 877-6322589, www.interlakemecalux.com. Booth 2012.

Reinforced construction enhances vertical carousel’s reliability Engineered 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 system failure and machine damage. The carousel is offered in multiple models for light- to heavy-weight applications, with warranties up to 10 years on some models. Sapient Automation, 800-6395805 www.GetSapient. com/Avenger. Booth 4231.

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Smart AGVs can be used in moving assembly lines SmartCart AGCs are flexible, low-cost automatic guided vehicles that can be used in assembly lines, to deliver pallets to and from stretch wrappers, roller conveyors and palletizers, 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.

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Laser bar code scanner debuts Offering 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 including 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 configurations 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, 800-2272633, www.accusort.com. Booth 2047.

Counterbalanced AGV for warehousing Developed for automation of pallet movement in warehouses, the counterbalanced automatic guided vehicle can pick up loads from the floor and block stack or interface with conveyors, stands and racking (standard single deep, pushback, flow through and drive-in). The warehousing 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 handle single or double pallets. JBT, 215-822-4600, www. jbtc-agv.com. Booth 3915.

Move workers, loads with mezzanine platform lift

Stand-up counterbalanced lift truck The models 4150 and 4250 stand-up counterbalanced lift trucks handle 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.

Traveling from 8 to 18 feet, a line of rider mezzanine lifts is offered. Ideal for moving workers with loads up one to two floors— or to high stages and mezzanines—the units include platforms ranging in size from 6 x 8 to 8 x 12 feet. Advance Lifts, 800-843-3625, www.advancelifts. com. Booth 2059.

WMS tool for reconciliation of test and production data For easier reconciliation of test and production environments in multiple sites, the environment 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.

Independent transport robot, gantry case/layer robot featured Capable 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 gantry 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. mmh.com

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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.

S H O W P RE V I E W Plastic holders for slotted bins protect labels Tri-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 without adhesive backing. The holders are offered five popular sizes to retrofit most standard bins. Laser inserts are included with printing instructions. A single package includes 25 holders. Aigner Index, 800-242-3919, www.aignerindex.com. Booth 1914.

Expanded pallet jack line A new line of pallet jacks ranges in capacity 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 adjustable push rods. Options include automotive brake attachments, load backrests and a choice of wheel configurations and materials. Clark Material Handling, 866252-5275, www.clarkmhc.com. Booth 2019.

Mini-load AS/RS includes two stacker cranes per level

Ergonomic workbenches, customizable A line of ergonomic modular workbenches and related products and accessories 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 requirements, accessories include adjustable metal shelves, footrests, louvered pan-

The Duosys mini-load automated storage and retrieval system includes tuning control 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 retrieval operations. The system can be laid out in two levels so that four SRMs operate simultaneously on the same rack, producing throughput of up to 2,200 cases per hour. Daifuku America, 866-414-2057, www.daifukuamerica.com. Booth 2003.

Give Your Heavy Pallets the Slip. ©2011 Rehrig Pacific Company

Material Handling Ship more product per load with Rehrig’s weight, space and cost saving Slip Sheets.

Come see us at ProMat Booth #3526

Rehrig co-extruded Slip Sheets are a cost-effective alternative to pallets. Impervious to moisture, high tensile strength plastic provides added tear resistance making them the perfect replacement for fiber or corrugated sheets, as well. Available in standard or custom sizes, Rehrig Slip Sheets provide superior slide resistance, keeping goods securely in place. Manufactured from nearly 100% recycled material, each sheet is also 100% recyclable. Beyond the sale, Rehrig can help you develop a customized re-use or buy-back program, further lowering your average cost per trip. Phone: (800) 546-4993 Email: [email protected] Web: w w w.rehrigpacific.com

Call us for more information about: Tier sheets, Liner sheets, Layer sheets, Cap sheets, Divider sheets, Pallet pads and Separator sheets

A fAmily trAdition of growth, service And innovAtion

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Two-toned bins for effective inventory control

Offered as a low-cost alternative to highend 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 inventory levels and the need for replenishment. 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 container Offered 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 transportation 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 products The 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-emission, cost-effective source of fuel from natural gas. Delivering quick refueling in less than 2 minutes, the systems produce consistent voltage throughout a shift, generating up to 10% gains in productivity. Nuvera Fuel Cells, 617-2457500, 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.

Need to DOUBLE Storage capacity? on ualizati s i V D 3emo @ D S M W 2011 ProMat 926 3 Booth # Automated Storage & Retrieval Systems (AS/RS) Savanna.NET® Warehouse Management Software (WMS)

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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 • 800-673-2522 www.WestfaliaUSA .com

OUR INNOVATION YOUR SOLUTION

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S H O W P RE V I E W Fast battery charging from high frequency system Using 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 minimize infrastructure investment. Compact, the charger’s small footprint frees up floorspace. It is always connected and fully networked, with a wireless communications interface for real-time battery and charger fleet management. EnerSys, 800-538-3627, www.enersys. com. Booth 1203.

Fit 315 collapsed containers into trailer Ideal for applications including manufacturing, plastic packaging products, food processing, dry goods and lightweight plastic components, the Maximizer reusable, collapsible plastic container holds

Palletizer redesigned for better ergonomics 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 alternatives. Buckhorn, 800-543-4454, www. buckhorninc.com. Booth 1219.

Control, monitor overhead cranes The LRC- M1 wireless control system for electrical overhead traveling cranes can control up to four motions with two ergonomic, 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 communicate 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.

For 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.southworthproducts.com. Booth 403.

Aigner. Look to the Leader in Label Holders. 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 FREE insertion on industrial shelving. Samples! 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. AIGNER INDEX Aigner Index Inc. 218 MacArthur Avenue New Windsor, NY 12553 Tel:1.800.242.3919 Email: [email protected] Fax: 845.562.2638 www.aignerindex.com

Open•Edge Hol•Dex

Write-On Wire•Rac Magnetic Cardholders

SuperScan Hi-Lo

Industrial fan delivers energy savings The durable and adaptable 8- to 24-foot diameter PowerfoilX industrial fan generates 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 visualization 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 visualization 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 strengthens 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 component 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 software The Omnii modular mobile computing platform allows the supplier, 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 platform 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 crane A 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.

STORAGE/STAGING

Steel lockers

SHOW PREVIEW Standard and custom containers A comprehensive line of plastic containers, bulk boxes, carousel containers, and vertical lift dividers are offered in more than 3,000 standard sizes and any custom 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.

manufacturer e and time Load transfer station handles 2 loads per minute

A 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 conveyor, transfers the load from one load base the conceptual System designers built in addito another, stacksdesign. the pallet and autotional flexibility for future expansion. The end result matically discharges the transferred load onto a19% conveyor. Transferred saved of the availableloads spacecan and more than half the thenand be stored in a high rise automated cost weight. storage and retrieval system, picked up downstream by a lift truck, or travel to Flexcon another operation. Columbia Machine, 800-628-4065, www.loadtransfer.net. 908-871-7000 Booth 972. www.flexcontainer.com

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Your work can’t wait. With Pro-Line’s “In Stock” Program, you can get the exact modular workbench your application demands in 5 days or less - with your choice of work surface, color, and many 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 height adjusting workbench, the popular Model HD, Dimension Next Modular Workstations, and more. • Configure your workstation with the exact accessories you need.

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 garments cool and dry, the locker features maximum ventilation openings. Lyon Workspace, 800-323-0082, www.lyonworkspace.com. Booth 659.

Warehouse management and control system A turnkey solution for warehouse control and automation, supply chain labor, and warehouse information management is offered through a partnership between the supplier and Softeon. The system improves order picking and inventory 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.

RIDER MEZZANINE LIFTS 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.

www.industrialworkbenches.com

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Increase conveyor speed with replacement spools

Pick-to-light for kitting, picking processes

For quick replacement of standard lineshaft conveyor spools, the split-speedupspool does not require disassembly of the conveyor to replace spools and spacer 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 feature 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 visually indicate which conveyor zones are moving faster. Dura-Belt, 800-770-2358, www.durabelt.com. Booth 352.

Intended for error-proof use in parts picking, 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.

Sort high densities at high speeds Offered with multiple tray configurations 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 sorting pharmaceuticals, books, multimedia, small packages, flats, shoes, jewelry, office supplies, e-commerce items, optical products, apparel and accessories. To

suit specific application needs, various induction methods and sorting destination types may be specified. EuroSort, 410-363-6345 www.eurosort.com. Booth 2619A.

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 product to hold it securely in place. Sealed Air, 800648-9093, www. sealedair.com. Booth 3919.

New module for RFIDenabled load tracking system The new Orchestrator work queue and task management module has been added to the VisiblEdge RFID-enabled system that automates data capture for location and identification 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 distribution and execution of material movement work instructions. Rush Tracking Systems, 913-227-0922, www.rushtrackingsystems. com. Booth 141.

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Intelligent jib moves with operator Offered as an easier-to-move alternative 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, 800-8210086, www.gorbel.com. Booth 3623.

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Workstation includes on-board power

FastPic5 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.

To run a computer, printer and other devices simultaneously, the PC series mobile powered workstation incorporates 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 different battery/inverter/charger packages. Newcastle Systems, 781-935-3450, www.newcastlesys.com. Booth 4768.

Live roller conveyor replacement belts The 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 existing belt. Habasit America, 678-288-3600, www.habasitamerica.com. Booth 1044.

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Easily identify inventory with clear view storage bins For 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,

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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.

Print, apply shipping label and packing slip For distribution and fulfillment centers, the TwinPrint system includes printers and printer applicators with two printheads that print both the shipping information 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 information 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 store Offered as an “app store” for the supplier’s warehouse management 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.

VLM offers Web-based inventory management Intended 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 included standard. Heights range from 10 to 50 feet, and custom models may be specified. The VLM incorporates intelligent inventory 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, 800-2751442, www.sencorpwhite.com. Booth 4407.

Repair floor cracks with deflection device The 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 environments. The units eliminate damaging deflection and permanently restore smooth, positive load transfer at all joints and cracks. Surface Dynamics, 800-584-5553, www.someromatsongroup. Booth 1274.

SV1.USA

SH O W PR EV IEW Five models of laser guided vehicles For high volume consumer goods manufacturers, 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 fourthgeneration 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.

Visit us at ProMAT Show 21 - 24 March, 2011 Booth #3203

Show pickers tasks, picks with visual WMS To 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, 800922-8649, www.tecsys.com. Booth 3872.

New products include tugger, heavy-duty workstation components, rollers 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

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 location. The pipe-and-joint system creates 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 accommodate totes with soft bottoms or open cell designs. Creform, 800-839-8823, www.creform.com. Booth 4814.

Charger for batteries The Legacy Titanium HF industrial battery charger uses advanced high frequency, insulated gated bipolar transistor charging technology. The charger delivers a high power factor 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.

The Evolution of the Motive Power Charger: LifeSpeed™. 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 You also get Battery Boss®, a compact real-time diagnostic system that attaches to the battery and provides detailed performance reports.

SPEED MEANS MONEY. Ask your HAWKER Representative to perform a Harness the Power Assessment™ to see if LifeSpeed™ is right for your application.

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

Visit HAWKER at Booth #1827 at the 2011 ProMat Show.

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SH O W PR EV IEW Single mobile computer performs multiple tasks Delivering 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 handheld 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 dataentry options, including a 3.5-inch touchscreen with stylus, 55 or 32 key backlit keypads, and voice technology. LXE, 800-6644593, www.lxe.com. Booth 4268.

ERP suite focused on cost reduction, process improvement

deniconda

®

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 [email protected]

The 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 enterprise 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.

System helps retailers plan assortments based on customer buying habits To help retailers predict consumer buying habits, the customerpreference 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 multiple software applications. Manhattan Associates, 678-5977274, www.manh.com. Booth 3668.

Zoned accumulation conveyor

denipro…

Unternehmen für fördertechnische Teile und Komponentenbau

General importer WRH Marketing Americas, Inc. 3150 Brunswick Pike, Suite 220 Lawrenceville, NJ 08648 [email protected]

For handling of medium- to heavyduty loads, a zoned accumulation conveyor features roll-to-roll chain driven live rollers. Zone lengths can be configured to coincide with the product 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.

Many conveyor manufacturers typically only make certain types of conveyors. At Capitol Conveyors, Inc. we know one size doesn’t fit all, that’s why we’re a full service, custom manufacturer of many different types of conveyors, including specials. We also offer complete solutions that include systems engineering, equipment, installation and commissioning – all with fast, flexible and efficient response times. •

Motorized DriveRoller



Lineshaft



Belt Conveyors



Belt Driven Live Roller



Chain Driven Live Roller



Gravity



Towers



In Motion Weighing



Automated Print & Apply

For More Information, Call:

877-532-9070

f s e e o er ot on ine qu to Eng rEE ject! lk Ta ales t a f t pro r S es ex ou requ ur n d yo an for

Need a Single Source Solutions Provider for Your Conveyor Needs?

S H O W P RE V I E W Rugged mobile computer

Offered in handheld and pistol grip versions, the Falcon X3 provides real-time data capture and communication for accurate inventories and enhanced productivity. It may be equipped with either laser scanner or 2D imager with a read feedback function to ensure accuracy.

To integrate seamlessly with WMS and ERP management systems, the mobile computer is packaged with Windows CE or Windows Mobile 6.5. For peak communication coverage, the device includes a Summit Wi-Fi 802.11 a/b/g radio with unique diversity antenna. Other features include numeric and alphanumeric

keyboards located at the operator’s fingertips, a universal numeric phone key layout, crisp display and backlit keyboard. The computer resists numerous drops from 6 feet. Datalogic Mobile, 800-929-7899, www.mobile.datalogic. com. Booth 4108.

Double handling capacity with spiral conveyor

InSight Ultra-Clear Bins ™

The choice is clear. InView Transparent, autoclavable polycarbonate for maximum visibility. InValuable Lock-in-place design for easy stacking. InReach Molded lip for hooking onto rails or louvered panels. InSide Optional clear lids and dividers for added versatility.

For more information, call 1-800-253-2467 or visit akro-mils.com/insight now.

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To handle double the capacity of the supplier’s standard products, a new high-capacity spiral conveyor has been introduced. The conveyors ship in one piece to reduce time and cost of installation. 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 energy, as well as controls and system integration, 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, 757-8981530, www.ryson.com. Booth 1523.

New swivel technology integrated into heavy-duty, forged steel casters Outperforming conventional CNCmachined ball raceways, kingpinless and unit-load bearing swivel constructions, a new swivel technology is offered on the supplier’s heavy-duty forged steel casters. Load capacities range from 600 to 23,000 pounds. The new HPI configuration 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. mmh.com

Modular, tear-drop connection storage rack

Pivoting shelves enhance capacity of mobile cart

A universally compatible, tear-drop pallet rack system includes four column profiles and nine popular beam sizes for maximum 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 positive beam-to-column engagement, all beams feature a patented, rugged automatic spring-lock pin mechanism. The racks are ideal for selective and high-density storage. Ridg-U-Rak, 866-479-7225 www.ridgurak.com Booth 1241.

The Tip-Up shelf cart includes integrated shelves that move and maneuver effortlessly. 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.topperindustrial.com. Booth 4564.

Electric trucks lift 4,000 pounds The E30-40XN series of electric lift trucks is available in 3,000 and 4,000 capacities. 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 technology for the traction and hydraulic systems, cost of maintenance is reduced. The thermal management system continuously monitors the controller and motor temperature and, upon identifying irregularity, the system protects the component 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 oriented to prevent pallet jack wheels from stopping on top of it, eliminating damage when misplaced pallet jacks are overpumped, 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 retardance. For a smooth finish, enhanced stiffness 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. mmh.com

Easily replace damaged panels on high-speed door Featuring easily replaceable, exchangeable panels made of vinyl, mesh, or clear PVC, G-2 high-speed roll-up doors can be repaired or modified 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 operations 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 conventional sensors that switch rack and warehouse lighting fixtures on and off, the InteLite dynamic sensor provides a safe transient mode that reduces typical aisle or storage 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, 800660-9340, www.oesx.com. Booth 1916.

Innovative Automated Solutions

www.interlakemecalux.com 1-(877)-MECALUX

Automated Vertical Storage Systems It All Adds Up To VALUE

S H O W PR EV IEW Compact scissor lift has 2,000-pound capacity The DXL series compact scissor lifts feature a smaller footprint than standard lifts while offering 2,000 pounds of lifting capacity. The lifts are ideal for work positioning, 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.

Wood block rental pallets hold 2,800 pounds Used by manufacturers and retailers throughout the U.S., Canada and Mexico, a wood block rental pallet measures 48

Before you decide to buy any Automated Storage System, go online and check out our pricing.

www.SPSSonline.com

It All Adds Up To VALUE

x 40 inches. Constructed with 26 boards and 138 fasteners per unit, the edgerackable pallets hold loads weighing up to 2,800 pounds. Features include 87% top deck coverage, non-slip traction in refrigerated areas, and no deflection in overhead 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 materials. PECO Pallet, 877-227-7326, www. pecopallet.com. Booth 2270.

Lift up to 50 tons with wire rope hoist

Lauyans & Company, Inc. 1-866-LAUYANS (528-9267) USA Manufactured

Truck series lifts up to 19,000 pounds

Offered 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 transmissions have smooth electronic inching to cut maintenance costs by eliminating periodic adjustments. Yale Materials Handling, 800-233-9253, www.yale. com. Booth 1003.

Modular vertical lifts debut

Small parts are expensive. Traditional shelving eats up valuable ßoor space and exposes parts. WhatÕs more, parts can be tough to Þnd and reach; keeping accurate inventories a challenge. The Lauyans Small Parts Storage System (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.

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 eliminate slack rope during operation, a fully enclosed free loop guide is incorporated. Columbus McKinnon, 800-888-0985, www.cmworks.com. Booth 1838.

A 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

Two new modular vertical 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 standard 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.

Voice software supports central application management Version 4.0 of Voxware 3 software for voice picking has been released, featuring an expansion of its voice management module. The upgrades enable the deployment and management of voice picking applications from a central data center across multiple warehouses of differing sizes and layouts. Other features include enhancements to order picking, replenishment, and putaway applications. To enhance open hardware support, the software also includes embedded, enterprise-grade AirWatch mobile device management technology, allowing for secure monitoring, management and support of all mobile devices in a fleet. Voxware, 609-514-4100, www.voxware.com. Booth 3672.

Automate dimensioning, weighing for shipping

IT’S MORE THAN A

WORK STATION...

... IT CAN SAVE UP TO 50% IN FLOOR SPACE. Building workstations with the Creform System of pipes and joints can significantly reduce the amount of floor space needed. Build TALK TO YOUR it for one person, a team of six or sixty, there’s no need to use CREFORM more space than necessary to complete the task. Over 700 Creform components help you expand within existing floor space. SALES ENGINEER ABOUT 42MM PIPE, DOUBLE YOUR LOAD W/O DOUBLING YOUR COSTS. See us at ProMat booth 4814 www.creform.com • 800-839-8823

CRE-356 4.5x4.625.indd To eliminate freight-carrier chargebacks, 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.

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✔ Better ❑ ✔ Safer ❑ ✔ More Productive ❑

Decentralized control for materials handling Movifit intelligent decentralized control combines with drive application and communication 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 environments. Preconfigured control routines for horizontal and vertical conveyor applications provide ready-to-use functions that simplify programming and start-up. SEW-Eurodrive, 864-661-1120, www. seweurodrive.com. Booth 1555. mmh.com

WITH GORBEL WORK STATION CRANES, YOU CAN HAVE IT ALL. • • • •

GORBEL, INC. 585.924.6262 [email protected]

Easy installation Modular design Superior load positioning 5-year warranties

800.821.0086 • www.gorbel.com Modern Mat eria l s Ha ndl ing / F

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A warehouse control system and new technology are the heroes at Simon & Schuster’s New Jersey distribution center. By Bob Trebilcock, Executive Editor

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modern system report

Simon & Schuster:

A twice-told tale E

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 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,” says Dave Schaeffer, vice president of distribution and ful-

“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.”

PHOTOGRAPHY BY JEFF FUSCO

very distribution center has a story to tell, especially one that’s gone through a significant system upgrade. Some have happy endings, some are thrillers, and some are mysteries (What were they thinking?). The story of Simon & Schuster’s 600,000-square-foot book distribution 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 materials handling equipment and technologies 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 control 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.

—Dave Schaeffer, vice president of distribution and fulfillment

GraphicCaption Feature

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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 division of CBS Corp. and one of the best

known names in consumer publishing, 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 independent 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 including 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

Narrow aisle racking and lift trucks make the most of Simon & Schuster’s storage space.

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600,000-square-foot distribution center in Bristol, Pa. For years, says Schaeffer, the publisher 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 working 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 distribution chapter through a step-bystep 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.

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modern system report

Cartons are delivered by conveyor to and from the order fulfillment and mezzanine areas in the facility.

Writing a new chapter The first of those steps involved gaining capacity. In 2000, the traditional pallet racks in Riverside were converted to a very narrow aisle (VNA) storage system 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 logistics 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 fundamental 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

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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 business 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 associate 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 accountability 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 paperwork. 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.

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Simon & Schuster relies on extendable conveyors to receive floor-loaded trailers.

With order fulfillment processes consolidated in Riverside, the Bristol facility now serves two functions. For one, it provides reserve and over-flow storage 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 business. As such, Schaffer sees only modest growth in sales volume, but tremendous 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-pallet 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 recognition technology has driven a new level of productivity and accountability in the piece picking area. “Prior to putting in the carton erector, we made all the cartons by hand in the pick zones,” says Schaeffer. “Now, 46

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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 capacity. “If the next zone is busy, the WCS will divert a carton to a zone that is idle to optimize the flow through the facility,” 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, voicedirected picking has brought improvements in productivity 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 facility, from the supervisors to human resources personnel and company executives, learned how to do voice picking. “Everyone has become an advocate for voice from the top levels of our organization on down,” says Schaeffer. In addition to throughput and productivity improvements, consolidating 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 warehouse,” says Schaeffer. “With engineered labor standards, we believe we can achieve greater productivity and greater pick rates.” M

As part of the latest improvements, voice recognition and a sophisticated warehouse control system were added to improve picking processes.

2 0 1 1 / Mo d e r n M ate r i a ls Handl ing

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modern system report Simon & Schuster

The book on distribution

Riverside, N.J.

Size: 600,000 square feet

The improvements allowed Simon & Schuster to synchronize manual processes

I

Products: Books, audio CDs Throughput: 11,500,000 units per month

n Simon & Schuster’s new materials replenishment orders throughout the handling system, a warehouse control warehouse based on the stock needs in and warehouse management system split case (4) and full case picking (5) (WMS) work together with bar code areas. To replenish the split case picking scanning and voice recognition tech- modules, for instance, the WMS directs nologies to manage inventory and orders. an associate to pick the required cartons Receiving: Simon & Schuster gets as if they were any other pick. The carclose to 100% advance shipment notifica- tons are labeled and inducted onto the tions (ASNs) from its printers. Inbound conveyor system (6) that delivers them freight is scheduled by appointment and to the back side of the pick module for prioritized by criteria such as how well an replenishment. item is selling. A shipment of a best-sellPicking: When it comes to picking, ing title, for instance, may be given prior- an order may be filled with a full pallet ity over a replenishment title. About 80% pick (3), split case picks (4), full case of the inventory received (1) in Riverside picks (5), or a combination of the three. arrives in full pallet quantities, although When the WMS creates an order, it the facility receives some returns and will generate tasks in three hierarchies. some print-on-demand titles on pallets For instance, if a customer asks for with mixed SKUs. Pallets are unloaded 1,057 books, and there are 1,000 books by lift truck. New titles that have never on a pallet and 10 books to a carton, the been stocked before are weighed and measured by the cubing and dimension3 ing system to create a profile for storReserve age in the WMS. Otherwise, a bar code storage label accompanying a pallet is scanned to determine a location on the dock where the pallet will be staged (2) for putaway. 4 6 Putaway: Once product is staged Mezzanine: 5 Split case on the dock, it’s putaway into storage picking Full case within 24 hours. Pallets are picked picking up in the staging area by the swing 10 reach trucks that operate in the very Sorter 4 narrow aisle storage areas (3) and are then directed by the WMS to 6 a putaway location. The operaSorter tor scans a check digit to con6 12 Special firm the putaway location and picking the pallet is now available in 11 9 the system. In the current Pallet build area configuration, full cases are 6 Conveyor picked from lower levels in system the storage area while the upper levels are used for reserve storage. 8 Staging for Replenishment: shipping Pick waves are run daily in the WMS system, 7 which also generates

Stock keeping units (SKUs): 25,000 Shifts: 3 shifts/5 days per week Employees: 225 in operations

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 supplying 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 scanning a bar code, he is directed to a staging

3

Reserve storage 3

Reserve storage

2 Staging for

receiving 1

Receiving

Shipping

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location (8) on the dock. Warehouse control system and voice recognition Carton picking: The system: AL Systems, www.alsystems.com Riverside facility stocks some Voice recognition engine: Voxware, www.voxware.com titles that are perennial bestVoice recognition devices: LXE, www.lxe.com sellers. These are stocked in a Warehouse management system: Manhattan special storage area (9) so they Associates, www.manh.com can be picked directly to the Conveyor system and sorter: Hytrol, www.hytrol.com Pushback, carton flow, pallet flow, drive-in and bin conveyor (6). For the remainrack systems: Frazier Industrial, www.frazier.com ing titles, picking instructions Narrow aisle (VNA) lift trucks: Landoll (Drexel), www. are delivered by the WMS to landoll.com/mhp/drexel/SL-50/ the operator on an RF termiPallet handling lift trucks: Hyster, www.hyster.com nal. Cartons are picked to a Mobile and fixed bar code scanning devices: Psion, pallet (5), and an operator may www.psion.com be picking multiple orders for Printers: Zebra Technologies, www.zebra.com multiple customers. Once the Weighing and dimensioning: Quantronix, www. pallet is full, the operator drops cubiscan.com it off at a conveyor induction area, where the cartons are loaded onto the conveyor (6). They are wrapped and staged (8) on the dock. Split carton picking: To initiate conveyed to a quality control area, where the cartons are weighed and compared to picking in the split carton area (4), cara calculated expected weight. Following a tons are automatically erected and labeled bar code scan, each carton is sorted (10) with two bar codes that can be scanned to a pallet building area (11) near the on two sides. The empty carton is then dock. Once the pallet is built, it’s stretch- sorted by the WCS to the right zone to

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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 circulate 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 cubing 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 pallet is built, stretch-wrapped and married to other components of the order on the dock (8). Shipping: Once all of the components of an order have been assembled on the dock, they are loaded onto a truck for shipping (7). M

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MODERN special report

Productivity Achievement

AWARDS M

odern’s annual Productivity Achievement Awards honor companies that have made outstanding strides in improving operations through materials handling and related information systems. 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.

Warehousing/Distribution Office Depot page 50

Manufacturing Rubbermaid Commercial Products

Innovation Cleveland Clinic

page 52

page 54

2011 WINNERS mmh.com

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MODERN special report

Warehousing/Distribution Winner

Office Depot:

Flexible automation Office supply retailer consolidates four locations into one new demand-driven distribution center that’s powered by mobile robotics.

W

hen Office Depot executives decided to consolidate 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 automated 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 solution 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 channels, including store replenishment and bulk deliveries Read the complete article at: www.mmh.com/article/flexible_automation

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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 system 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 scratch Office Depot is a leading supplier of office products and services, 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

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modern system report

Photography by Alan Wycheck

came in two styles: crossdocking centers to replenish retail locations and DCs to service business customers and direct-toconsumer 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 facilities 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 building a new facility. Guerrero and Beabout wanted a system that could integrate with its homegrown warehouse management system to handle every line of business and sales channel where it operates. And, they wanted the flexibility to scale during 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 network. In the new pull model, every store will get a just-in-time delivery nearly every day of the week.

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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 workstations, and a larger vehicle designed to handle full pallets. Once picks have been completed, the robots deliver the units to a conveyor induction station, where the shipping containers are placed on a conveyor and sliding shoe sortation system and are sorted to a shipping 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 accurate, which would reduce picking errors. Dynamic slotting: The robotic system monitors the movement of SKUs and slots the fastest moving items closest 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

Bob Zelis, senior director (left) and Brent Beabout, vice president of global network strategy and transportation

system in the future. While mobile robotics is providing answers in Newville, that doesn’t mean Office Depot will adopt the technology 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.”

System suppliers Mobile 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 warehouse management system

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MODERN special report

Manufacturing Winner

Rubbermaid:

Manufacturer retrofits warehouse with AS/RS By updating an aging manual storage system with automated cranes, Rubbermaid Commercial Products reduced costs and improved safety.

R

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 operated, 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 certainly 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. Read the complete article at: www.mmh.com/article/rubbermaid_products

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It was a textbook example of solid design and project management coming together to deliver productivity gains with materials handling automation. Time for renewal Winchester, 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 maintenance 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 products. 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 pallet 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 components, materials and work-in-process to support manufacturing 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.

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modern system report The right solution In 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-andbeam 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 storage 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 project Between November 2008 and April 2009, Rubbermaid assembled a project team that included operations, maintenance and IT, and representatives from relevant vendors. IT representatives planned how different systems would communicate 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, programmable 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 opportunity 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 outbound 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 foundation By February 2009, the cranes were in production. Rubbermaid began installing wiring and data drops for the controls and machines and welding 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 System Rubbermaid’s biggest load. Implementing the system In May, the first aisle was shut down to install the first crane. It took three weeks, and required only minor modifications and changes to the logic in the WMS to better match the physical locations to the product. 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 equipment that accommodates our needs today and will grow with us in the future,” says Elliott.

John Elliott, senior distribution engineer

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

PHOTOGRAPHY BY JEFF Hutchens

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MODERN special report

Innovation Winner

Cleveland Clinic: A prescription for health care reform

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.

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sign outside the new 227,000-square-foot service 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 director of materials management for the clinic, one of the nation’s premier medical facilities. “We are picking an average 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 visited medical centers in Europe to design a system with capabilities 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. Read the complete article at: www.mmh.com/article/cleveland_clinic

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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 carousel 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 warehouse 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 speed Founded 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 cardiac and urology facilities. With the anticipated increase

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Jeff Pepperworth, senior director of materials management

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 management, pharmaceuticals and surgical 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 deliveries 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 bringing new facilities online. • Implement with no shutdown:

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Finally, the clinic needed to operate 24/7 while implementing new systems. A new model From the start, the team was working without a template: Pepperworth and his colleagues visited health care facilities 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 handling 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 system captures data throughout the delivery process. In addition to an RFID scan by the AGV, associates scan a personal 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 confirm accurate delivery. The system was operational from day one. And as the clinic continues its mission of delivering quality care, the warehouse is supporting that mission. M

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modern productivity solution

LEAN and green pallets With a presswood pallet, Lincoln Electric is not only meeting European export requirements and streamlining its pallet inventory, it’s reaping sustainability benefits. By Noël P. Bodenburg, Executive Managing Editor

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incoln Electric, a Cleveland-based manufacturer of arc welding machines and consumables, was looking to better meet export shipping requirements 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, manufacturing engineering manager for Lincoln Electric. In addition to maintaining an inventory of nine different 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 number of benefits to Lincoln. The pallets are manufactured using an environmentally responsible process 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 product,” says Soster. “On our first shipment, we learned that presswood pallets are common and welcomed in Europe. It was a very easy transition.”

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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 estimated 5% savings on the cost of the pallets. And, Lincoln can order the pallets on an as-needed, justin-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 meeting our shipping requirements, it’s making us a little more green.” M mmh.com

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Protective rails installed at the base of a rack system can safeguard against accidental impact and damage.

modern Equipment 101: Pallet rack A primer for warehouse/DC managers

Behind the backbone Pallet rack is a fundamental By Lorie King Rogers, component that can Associate Editor maximize storage space and have a positive impact on organization, productivity and throughput in your facility.

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f 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 skeleton 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 facilities 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 traditional 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. mmh.com

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modern Equipment 101: Pallet rack A primer for warehouse/DC managers

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. Steel structural

Rollformed

Uprights Welded

Company

Web Site

Telephone

Headquarters

Advance Storage Products

advancestorage.com

888-478-7422

Huntington Beach, Calif.

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

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

Pacific Westeel

pacificwesteel.com

866-473-3472

Oakville, Ontario, Canada

Penco Products

pencoproducts.com

800-562-1000

Skippack, Pa.

Ridg-U-Rak

ridgurak.com

866-479-7225

Schaefer Systems International

ssi-schaefer.us

SPG (formerly Jarke) SpaceRak

x

x

x

x

x

x

North East, Pa.

x

x

x

800-876-6000

Charlotte, N.C.

x

x

x

spgusa.com

800-722-5255

Prospect Heights, Ill.

x

spacerak.net

800-336-3926

Wills Marysville, Mich.

x

x

x

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

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between the upright frames. Two frames and the corresponding beams create a bay. The number of pallet positions 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

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x

x

x

Speedrack Products speedrack.net Group

handling industry. Variations of these steel structures keep product organized, provide storage, and maximize cube space from floor to ceiling. More importantly, they are central to getting product out the door. “A good rack system literally and figuratively supports 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

Bolted

x

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 common in the United States. Structural steel typically costs about 5% to 10% more than roll-formed. According to Olson, raw materials make up a significant part of the cost of rack. For that mmh.com

modern Equipment 101: Pallet rack A primer for warehouse/DC managers product. Here’s look at what the different systems offer.

LOW-DENSITY RACK Single-deep rack Single-deep rack, or selective rack, is the most common type used in warehouses and distribution centers. Since loads are stored one pallet This high-density pallet rack storage system uses an deep, this is the lowelectric cart to load and unload pallets, saving time and est density storage minimizing forklift incidents. of any system, but it reason, any increase in the price of allows unimpeded steel will drive a percentage increase in access to every pallet. It can be used the cost of the finished rack. in a number of aisle configurations and Rack systems can generally be divided can be paired with any type of lift truck. into two broad categories: low-density Single-deep pallet rack is also the systems that allow easy access to product, least expensive rack option. According or high-density systems that make better to “Rules of Thumb,” a pricing guide use of space but limit access to stored published by TranSystems, standard

selective pallet rack costs about $50 to $75 per pallet position. Double-deep rack Aptly named, double-deep rack stores one pallet load behind another in a structure that’s twice as deep as singledeep. 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 pallets 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 doubledeep 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 RACK Drive-in rack Drive-in rack can be configured to store loads four or more deep, creating very

Protect the code, track the load

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treamlined movement in and around pallet racking is crucial to an operation’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 environment, 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 customer relations. One simple solution for bar code protection is clear insertable plastic label holders. Available in many styles, these holders typically cost less than 5% of the total warehouse expenses and can generate returns in improved productivity, inventory accuracy, knowledge of product location, and flexible designation or location changes. Once product is located, tracking its

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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.

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 president of marketing for Sky-Trax (www. sky-trax.com). To determine the location of a forklift, a sensor mounted on top of the vehicle reads the optical position markers 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 questions 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.

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modern Equipment 101: Pallet rack A primer for warehouse/DC managers 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 without 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, perpendicular to the aisles. Pallets are stored on a last-in/firstout basis. Each bay is typically dedicated to a single product, so drive-in rack is best used for storing large quantities of the same product. They work well where an entire bay of product is moved at once, such as in staging product for shipping. According to “Rules of Thumb,” standard 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 rack Drive-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 firstin/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 STORAGE Gravity flow rack Gravity flow rack combines a stationary rack structure with skate wheel or roller conveyor to create a dynamic storage system. 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. 64

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R-Mark marks the rack

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f good rack goes bad, the results can be catastrophic, even deadly. So pallet rack suppliers have established strict technical guidelines to ensure product integrity and overall safety. To be sure the rack you’re considering meets these guidelines, look for the R-Mark. The R-Mark Certification program 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 manufacturers must submit sets of product data which is studied by RMI engineers to

ensure the suppliers’ testing, calculations 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).

Flow rack systems provide highdensity storage by storing product many pallets deep. Because each layer of flow rack is typically dedicated to a single product, these systems offer less storage 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 available 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 position for systems two loads deep and $250 to $400 for three or more loads deep.

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.

Push-back rack Push-back rack combines a stationary rack structure with nested carts that move along inclined rails. The first pallet, 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 pallets deep, these systems offer dense storage. Like flow rack, push-back rack does not require a lift truck to enter the

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Protect your investment With 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/industrygroups/rmi). All rack manufacturers offer a variety of options and accessories that reduce potential damage to rack structure, he says, and advises making the investment in protection. Don’t skimp on protection or prevention. “Nothing lasts forever, and wear and tear can take its toll,” adds Curry. “Actually walk the aisles and inspect your rack frequently. This preventive step could save a major headache later on.” M mmh.com

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modern special report

: y e v r u Reader s 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. By Bob Trebilcock, Executive Editor

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hen it comes to automated materials handling 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.

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Here are the most important results. From belt to towline From 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% are using belt conveyor. • 63% are using roller conveyor. • 62% are using accumulation conveyor. • 53% are using motor-driven roller conveyor. • 47% are using chain conveyor. While fewer readers have installed sortation systems, the mix among those who have is fairly evenly divided among the different speed offerings, measured in cartons per minute (cpm). • 26% are using medium speed sortation (50 to 150 cpm). • 24% are using high speed sortation (150 cpm and up). • 20% are using slow speed sortation (up to 50 cpm). When it comes to future conveyor purchases, the picture

remains much the same for the next 18 months: • 60% plan to purchase belt conveyor. • 41% plan to purchase motordriven roller conveyor. • 40% plan to purchase roller conveyor. • 39% plan to purchase accumulation conveyor. • 30% plan to purchase chain conveyor. Planning for the future Caution seems to be the watchword when it comes to future investments in conveyor and sortation systems. With the economy beginning to grow again, a segment of Modern’s readers is planning to spend more (23%) or the same (30%) on conveyor over the next 18 months than they spent in the last 12 months. Another 22% are taking 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

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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-newsletters. 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% of those planning to purchase new conveyor will use it in a manufacturing plant, • 40% will use it in a distribution center, and • 30% will use it in a warehouse.

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modern special report 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 handling 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 purchasing the equipment for a new facility and 61% say their purchase is part of an expansion project. The majority of those purchases

Which of the following types of conveyors are currently in use at your facility? 80% 75%

Belt 63%

Roller 53%

Motion-driven roller

52% 47% 48%

Accumulation Gravity flow Chain Pallet Spiral Medium-speed sortation High-speed sortation Slat Low-speed sortation Power-and-free

38% 34% 29% 26% 23% 26% 21% 24% 18% 22% 19% 20% 25% 20% 26%

74%

59%

58%

47%

December 2010 February 2010

Note: Low Speed Sortation: up to 50 cpm Medium Speed Sortation: 50-150 cpm High Speed Sortation: 150 cpm and up

How is the economy impacting your spending on conveyors and/or conveyor parts and accessories? Will be spending about the same as as in 2010 on conveyors in 2011

30%

Will be spending more on conveyors in 2011

23%

We are taking a 'wait-and-see' approach and not planning to invest at present

22%

Overall materials handling budget has been cut in 2011 Will be allocating more on maintenance Will be spending less on conveyors in 2011

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come directly from a conveyor manufacturer (54%) or conveyor distributor (39%). The same holds true when it comes to replacement or spare parts, with 46% purchasing directly from a manufacturer 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 facility may be down until that conveyor is back up and running. It comes as no surprise then that reliability was considered “very important” (72%) or “important” (25%) by more readers than any other attribute. The reputation of the supplier was a distant second, ranked as very important 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 technology 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 intelligent conveying features (32%) in their systems. Up and running Conveyor manufacturers, like lift truck providers, have been developing new maintenance programs for their customers. Still, Modern’s readers are mostly taking care of business when it comes to keeping their conveyor systems up and running. • 81% use their own crew for maintenance. • 8% have a service contract with an OEM/supplier.

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modern special report

Approximately how much did you spend on conveyors and/or conveyor parts and accessories during the last 12 months?

How much do you estimate you will spend on conveyors and/or conveyor parts and accessories in the next 18 months? $297,000 $300,000

$261,000

$81,000

$75,000

$55,000

9%

13%

14%

11%

7%

6%

7%

20%

18%

61%

61%

February 2010

December 2010

Average $

$263,000

$321,000

$255,000

Median $

$80,000

$92,000

$76,000

10%

13%

6% 22%

7% 26%

18% 65%

62%

7% 18% 64%

$1 million + $500K-$999 $100K-$499