Coming Generations Material Handling Equipment PROJECT REPORT Ferdinand Aichrielder
MFA Advanced Product Design 2017/18 in cooperation with KALMAR
Table of contents
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CONTENT Titel page 02-03 Table of contents 04-23 Research Journey Poland, Germany, Sweden Analysis & Synthesis Conclusions Abstract 24-20 Introduction 20-30 Project background Method 30-40 Initial research Problem analysis Conclusions Goals and Wishes Results 30-40 Inspiration/image boards Ideation Mock-ups 3D digital modelling Reflection and conclusions 30-40 The project Work process & learning References 30-40 Appendices 30-40 Time schedule
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Abstract To get a better understanding of our porjects context, we were invited by Kalmar to explore different applycations of their products. The trip started in Swinoujscie, Poland. We got introduced to Kalmar. After a presentation about the company we got introduced to the project brief. Thereafter the research continued with a guided factory tour and a first hands-on with the machines. The next two research days were held in Hamburg. Several container handling companies have been visited. We interviewed logistic manager, mechanics and drivers. AcelorMittal was our last stop in Hamburg. We saw the use of Kalmar machines in a steel production factory. The end of our research week was closed with a saw mill visit back in Umea. After the focus area “automated forklift in a saw mill context� was chosen, additional research has been done. The main concept is to reduce the mass of forklifts bei shifting weight to the center. This allows to use smaller counterweights and therefore reduce the stress on the ground. The design process was consisted of ideation, CAD and was concluded with a physical model.
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Introduction
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Introduction
KALMAR Mobile equipment Kalmar products and services are used in ports, terminals, distribution centers and in the heavy industry. Kalmar products include forklifts, terminal tractors, quay cranes, yard cranes, ASCs (Automated stacking cranes), shuttle and straddle carriers, reachstackers and equipment for empty container handling. Lately, Kalmar has invested in terminal automation and in energy-efficient container handling. The focus in this project lays on Kalmar’s mobile equipment. How these machines could look, work and define Kalmar’s business in 15 years is the core aim.
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Img. 03 Thomas Müller
Method
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Research Journey
UMEĂ… Sweden
To get a better understanding of our porjects context, we were invited by Kalmar to explore different applycations of their products. The trip started in Swinoujscie, Poland. We got introduced to Kalmar. After a presentation about the company we got introduced to the project brief. Thereafter the research continued with a guided factory tour and a first hands-on with the machines. The next two research days were held in Hamburg. Several container handling companies have been visited. We interviewed logistic manager, mechanics and drivers. AcelorMittal was our last stop in Hamburg. We saw the use of Kalmar machines in a steel production factory. The end of our research week was closed with a saw mill visit back in Umea.
HAMBURG 12.
Germany
SZCZECIN Poland
UNDERSTANDING THE USER Travel to Poland & Germany Tuesday October 31st, Swinoujscie Project Start-Up & Factory tour Wednesday November 1st, Hamburg Multipurpouse container handling Buchardkai, empty container handling Thursday November 2nd, Hamburg Steel factory, ArcelorMittal Hamburg Friday November 3rd, Hamburg Saw mill, Vännäs Sweden
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User Study A Kalmar factory, two container terminals, a steel prdoction & a saw mill have been visited on a five days research trip.
KALMAR FACTORY Poland, Szczecin
MULTIPURPOUSE TERMINAL Hamburg, Germany
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BURCHARDKAI CONTAINER HANDLING
ARCELOR MITTAL
SAW MILL
Hamburg, Germany
Vännäs, Sweden
Hamburg, Germany
EMPTY CONTAINER HANDLING Hamburg, Germany
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Kalmar Factory Szczecin, Poland
Our reserach trip started with the arrival at the Kalmar factory in Szczecin, Poland. In the morning we received a presentation about Kalmar and their goal about this project. After that we took a tour through Kalmars factory, where we saw how these big machines come together. Kalmar produces the parts mainly in China and then brings them to Poland for the assembly. The factory visit was concluded by showing us the reachstackers, forklift trucks and terminal tracktors in action.
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Multipurpose Terminal Patrick A. gave us an insight into his daily workflow. He is a logistics manager at a middle sized multipurpose terminal in Hamburg. Ships with up to 10.000 containers arrive in the harbour. Cranes lift the containers one-by-one off the ship. The waiting terminal tracktor receivs the container from the crane and drives to the storage location. A reachstacker then picks up the machine and puts it into the storage location. After we saw the unloading process at the harbour, we got the chance to talk to the mechanics, Tobias Z. He told us that after they installed a technology called “one key”, drivers started to take care of the machine more. “one key” tracks who uses the machine and makes it easier to associate damages to drivers. Mechanics repair the machines after 5000 working hours. The tyres get switched from the outside to the inside to equal wear and tear.
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PATRICK A. 42, Logistics & Management
Issues: Crane drivers change in 4 hours shift, since they start to get neck pain from looking down.
TOBIAS Z. 40, Mechanics
Heavy machines create damage to the ground. The opening for filter replacement is too small, and adds an increasing amount of maintenance time. Opportunities: Adjustable cabin, to avoid neck pain. Create a bigger opening for the filter replacement.
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Buchardkai/ Empty Container Handling The empty container handling facility is located on the areal of Hamburg’s harbour. The main task is to get empty containers by trucks then bring move them to their dedicated storage location. Kalmar produces machine especially for these businesses. They are called “empty container handlers”. Containers get stacked up to 9 rows. The higher the containers are the harder they are to handle. The main risk is that they fall backwards on to the drivers cabin.
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“In 5-10 years empty container handling wi
Issues: Uneaven stacking creates safety issues for the next driver who picks up the container above. Putting the last container on top creates a risk of the container falling on to the cabin.
Empty container handlers can maneuver 2 containers at the same time. The drivers cabin is located on a higher position compared to fother container machines. This gives the operator a better overview at the harbour.
ill be an automated process� - Michel
MIKE G.
MICHEL S.
35, Forklift driver
35, Logistics & Orgnanization
Opportunities: Guidance through sensors, to improve stacking precission.
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Steel Factory Arcelor Mittal In the beginning of our visit at the steel factory “Arcelor Mittel” Marc S. gave us a brief overview about the steel manufacturing process. After a long process raw materials like manganese, nickel, carbon or torgon end up in a 2t heavy coil. These coils are then stored until they get picked up by a forklift and then brought to the pick-up area. Embedded in Hamburgs harbour, Arcelor MIttal uses ships to transport the main part of their products. Other means of transportations are trucks and trains.
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“I have no view to the back, so my coworkers hear the noise and know that I am there” - Heinz G.
Issues: A lot of machines in a dense area.
“The environment is too human right now.� - Marc S.
Two people are needed for one task. The labeling system is complex and time consuming. Stressful work during peaks, lead to human errors Opportunities: Rear driving sound design. Use sensors for reading labels.
HEINZ G. 52, Forklift driver
MARC S. Logistics & Management
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Saw mill Brattby Sågverks The last stop of our research trip was at the “Bratty Sagverks AB” in Vännäs, close to Umea. 5 medium sized forklifts were in use. One of them was from Kalmar. Mikael E. showed explained us how he uses the forklift on a daily basis. In the saw mill industry it is common to use RFI-Tags under each pile of wood in order to ease the logistics process. When the forklift approaches a stack of wood it recognizes the tag, therefore the driver does not have to manually input the information. The saw mill forklifts are have specific additional features like, fire extinguisher and sand boxes above the front wheel. When opened, these sand boxes can create extra traction in winter conditions.
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“Weight dictates the purpose” - Mikael B.
“Its always a danger with these forklifts” - Mikael B.
MIKAEL B. 35, CEO
MIKAEL E. 22, Forklift driver
Issues: Fixed forksize makes it hard to pick up different lenghts of stacks. The ground suffers under the weight of the machines. These ground damages then impose risks for driving safety. Opportunities: Create lighter machines, that are still able to lift the same weight. Adjust the fork length.
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Analysis & Synthesis STORYBOARD Creating a fictional persona.
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COMPETITOR ANALYSIS
MAPPING ISSUES
BRAINSTORM IN GROUPS
Identifying and highlighting insights
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Conclusions
MAIN ISSUES
INDUSTRY CHANGES
Machines weight
Automation
The machines weight creates a big problem for the ground. Changing the architecture of the machine may lead to new solutions for weight reduction.
The material handling industries are going to face major challanges the next decades. All human controlled machines are going to be automated sooner or later. This creates a big opportunity for kalmar. They can lead the shift from manual operation to automation.
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Areas of Inerest
AUTOMATION
INTERACTION
IDENTITY
No cabin creates new opportunities for the vehicels architecture.
People that are outside of the forklift have eye contact to the forklift driver to communicate.
Forklift as a physical brand manifestation of kalmar Influence of new technology on the product
How can people communicate with an autonomous forklift? How can trust be created?
Form Sound Graphics Color Light
There might be an opportunity in lifting the load towards the center of the machine, to reduce the counterweight and be more agile.
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Goals & Wishes
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GOALS
WISHES
Show a wide range of ideation. Form development.
Apply the defined brand language to other kalmar products, by showing side view renderings.
Create new iconic brand identity for Kalmars automated forklifts. Visualize new opportunities of grabbing and moving material.
Show specific products for more than one industry ( saw mill, paper mill, steel facotry)
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Additional Research
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Forklift Layout
Cabin
Mast Engine
Fork
Fueltank
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Counterweight
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Forklift Attachments There are several different attachments for forklift currently on the market. They range from steefactory, papermill to sawmill. Each attachment is designer for the speciffic requirenments.
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Sawmill
SURFACE-PLANING FACILITY Workshop Intake Bring stack to intake
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Workshop Outtake Pick up processed wo
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Stac Stat Pre stac Lorry loading Put stacks onto the lorry
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WOOD STORAGE
Wood Storage Pick up Stack of wood
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ood
cking tion epare two cks for transport
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Results
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Concept Variations
A Moving in
Pros & Cons +less mechanics -classic
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B Swiss knife
Pros & Cons +more compact +new approach -sophisticated mechanism
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Kalmar Product Identity
The Cargotec elephant stands for strength, long life, reliability, trust and lifting. logotype has a long history starting from year 1971, significant brand recognitio
KALMAR’S ELEPHANT strength, long life, reliability, trust & lifting.
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KALMAR’S HISTORY KALMAR RED #1234234234
It also has a strong connection to nature and sustainable actions. The on and value.
SIGNATURE ELEMENT
WHEEL ARCHES
counterweight
Two blended arches
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New Identity 2030 Kalmar’s current products are created out of big surfaces. They create many sharp edges, which give the expression of rough almost aggressive appearence. The engine is covered with a more defined , performance expressing surface. The center of Kalmars machines is clearly visible the drivers cabin.
CREATING ROUNDER TRANSITIONS rear part of the forklift
In a future without a drivers cabin and no human operating the machine, a transition from a rough and strong appearance to a more helpful and assisting formlanguage is desired. This will help the people on site to trust the operating machine.
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OLD
NEW
edges, rough
rounded, friendly
FROM EDGE TO ROUND
fearful rough aggressive
approachable friendly helpful
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Identity Essence
APROACHABLE friendly helpful communicative
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AGI
intell qui lightw
ILE
RELIABLE
igent ick weight
strong adaptive robust
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Graphic Identity
+ Kalmar’s old logo heritage
I&O Input / Ouptut
Innovation
Kalmar Kio Sub-brand for Kalmar’s automated vehicles.
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Identity Graphics on the rear of the forklift
Side graphics, incl. costumers personal branding
Kio, Kalmars new future oriented branding.
The new Kalmar “K.� prominently placed on the mast. 51.
Applied Graphic Identity
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Applied Graphic Identity
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Tyre Pattern
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Securtiy HOW TO CREATE TRUST FOR IN THE MACHINES?
WEARING A VEST WHEN ENTERING THE SAW MILL
Safety System Nowadays human workers on the site wear a reflective west increase visibility. In the future there has to be a special kind of “Kalmar-Security vest”. Maybe similar to an existing vest, but with integrated location sensor and lights. You can only enter the saw mill if you wear a “connected Kalmar vest”. Feeds the location data of all humans on the site into the system and reduces the risk of accidents.
CONNECTED KALMAR VEST
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light feedback
haptic feedback (vibration)
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Ideation
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CAD process
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Keysketch ..
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Environment Sensors Wtih the help of environment sensors the forklift can create a 3D map of its surrounding and therefore locate obstacles along with identifying the loading area for wood stacks. The LiDAR sensors are located in the top of the mast as well as in the front and back wheelarches.
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Rear Light & Rear sensors In the rear wheelarches light and rear sensors are situated. The sensors make sure that there is enough room for extending the counterweight and the rear light signals surrounding people the movement.
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Round form language A big focus of this concept was on the round friendly form language. Sharp edges have been avoided to create the appearance of a more approachable machine.
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Appendices
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Timetable
44 45 46 47 48 49
Creative workshop Design brief In depth research Atutomation Saw mill process Ideation Structure Verbal CAD Package Surfaces Details Workshop Foam Paint Presentation
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10 13
17 20
24 27
01 04
Ideation Presentation
Research journey
03 06
Research Debrief
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50 51 52 01 02 03 22 25
29 01
12 15
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Internal presentation
05 08
Final Presentation
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Concept Presentation
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Christmas 2017
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