AUTUMN 2017 €4.95 inc. VAT Autumn Vol XVVIV
The Irish Magazine for the Materials Handling, Warehousing & Logistics Sectors
Featuring: - News & views - Viewpoint - Review: Transport Logistics - Safety
- Awards - UKWA & IFOY 2017 - Case Studies - Logistics - Supply Chain
Whatever your business
TOYOTA – TRUSTED BUSINESS PARTNER. Toyota Material Handling Ireland now brings to the market the complete range of Toyota counterbalanced forklift trucks and BT warehouse equipment, supported by services and added value solutions offering the customer a one stop shop for all your material handling needs. From hand trucks, pallet trucks, order pickers and reach trucks to gas, diesel and electric counterbalance trucks, we offer you the widest product range in the business, making Toyota Material Handling the ideal partner for your business, whatever it is. www.toyota-forklifts.ie
www.toyota-forklifts.ie or Toyota Material Handling Ireland at Toyota Ireland, Killeen Road, Dublin 12. Tel: 01 4190200.
contents AUTUMN 2017 The Irish Magazine for the Materials Handling, Warehousing & Logistics Sectors
Volume XVVIIV Issue 3
6
4
12
4
News
6
Viewpoint: Peregreen
8
Review: Transport Logostics
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Safety: HSA
14
Awards: UKWA
16
Awards IFOY 2017
18
Case Studies
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Logistics: E-Commerce
22
Supply Chain: IEA
22
8 Published by:
Fleet Publications, D’Alton Street,
Claremorris, Co. Mayo, Ireland F12 E7P2
Editor:
Jarlath Sweeney – jarlath@fleet.ie
Contributors:
Johanna Parsons, Paul White, Howard Knott,
UKWA/AIWA, HSA, IEA
Advertising:
Mary Morrissey
Administration:
Denise Owens
Design & Layout: Crackerjack Design House Contact Details: Telephone: 00353 94 9372826
Email: handlingnetwork@fleet.ie
WHO GETS HANDLING NETWORK? Handling Network - the magazine of the Irish Handling & Distribution Industry - is produced bi-monthly by specialists in the materials handling sector, with contributions by experts on topics of special interest to its readership. Handling Network is distributed on controlled circulation; addressed to key personnel in Ireland’s top companies and organisations. Recipients include Company Directors, Purchasing Managers, Warehouse & Logistics Managers, Plant & Production Engineers, Transport Managers, Safety Officers and other relevant personnel. Areas covered include forklift trucks, warehouse logistics, racking, storage & distribution, commercial vehicles, plant & equipment finance, lifting gear, loading bay and conveyor systems...together with information on health and safety issues.
Although every effort is made to ensure the accuracy and reliability of the information contained in Handling Network, the publishers cannot accept responsibility for the veracity of claims made by advertisers, manufacturers or contributors or for opinions expressed. Copyright for all material contained in this magazine remains with the publishers.
www.handling-network.com
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AUTUMN 2017
news
UKWA opens its doors to retailers and manufacturers
John Lewis, Homebase and Claire’s Accessories are among the first retail companies to sign up to the United Kingdom Warehousing Association’s (UKWA’s) new membership category that allows retailers and manufacturers which manage their logistics and supply chain operations ‘in house’ to become part of the association. Originally established as a trade body for the third-party warehousing and logistics sector, UKWA’s membership has, until now, only been open to those companies that provide outsourced third party logistics (3PL) services, together with suppliers of products and equipment used by the warehousing industry. The organisation’s Irish affiliate is the All-Ireland Warehousing Association.
However UKWA membership is now no longer restricted to companies operating in the third-party logistics and warehousing sectors. Essentially this means companies that undertake warehousing and logistics tasks but for whom such operations do not represent their core business – such as retailers, manufacturers and wholesalers - are now free to join the association. “The decision to open our ‘doors’ to companies whose primary business is not logistics has been driven by the demands of retailers and manufacturing companies who want access to the best practice advice and knowledge that UKWA can provide,” explained UKWA’s CEO, Peter Ward. “Brexit aside, the logistics sector is facing a period of unprecedented
and rapid change and it is important that companies in the retail and manufacturing space are able to work with UKWA and its 3PL members as we all strive to shape Britain’s supply chains and respond to the many opportunities that lie ahead, while managing the prevailing risks of uncertainty,” he continued. “By opening up its membership criteria, UKWA will become a forum where retailers, manufacturers and 3PL service suppliers can exchange ideas and this can only benefit the development of the modern supply chain. Of course, we expect the overwhelming majority of UKWA’s members to remain third party warehousing and logistics services companies, but the move to widen the association’s membership eligibility means that UKWA is now truly representative of the wider supply chain community.” For details of UKWA and the benefits of membership, please visit www.ukwa.org.uk
Hoppecke – 90 years strong Hoppecke Industrial Batteries is celebrating 90 years of battery manufacturing. Since 1927, Hoppecke has been producing energy storage systems in Brilon in Germany. At a special ceremony, Hoppecke’s Managing Director, Dr. Marc Zoellner and his father Claus, who led the company for 37 years until 2003, accompanied by 20 former employees who are all older than 90 years of age, watched the
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company’s jubilee flags being raised in Brilon. The official birthday celebrations will take place on 27 September. Jason Howlett, Hoppecke’s Regional Managing Director - Northern Europe, said: “This is a momentous occasion, the Hoppecke parent company being in business for 90 years. We are proud to
be involved in these celebrations which underline the longevity of Hoppecke and the unrivalled level of experience and expertise that exists within the company.”
AUTUMN 2017
news
FLTA promotes #SAFE2017: Save life and limb
Despite having some of Europe’s tightest safety regulations surrounding workplace transport, three workers in the UK are hospitalised with serious injuries each day as a result of fork lift truck accidents. “We’re not talking cuts or scrapes. The nature of fork lift trucks means you don’t just walk away from a fork lift truck accident. Those involved in accidents – and there are more than 1300 of them each year – suffer
New Merlo & Komatsu Salesman at McHale Plant Sales Merlo distributor, McHale Plant Sales has appointed John Cahill as sales representative for Merlo telehandlers and Komatsu mini diggers. Operating from the company’s
long-bone fractures, amputations, degloving and much worse,” stressed FLTA Chief Executive Peter Harvey. “It’s an untenable situation… and it really is down to each and every one of us to make every effort to change it.” At the National Fork Lift Safety Conference (#SAFE2017), a large portion of the programme focused on individuals who, despite the challenges, have done their best to improve the safety of their operations. Rowlinson Knitwear has made substantial improvements to its warehouse safety in recent years.
Recently, the Stockport business, the UK’s market-leading manufacturer in personalised schoolwear, has undertaken the following initiatives: Bespoke training: Training – including warehouse safety – has been developed internally to raise awareness. Narrow aisle safety: Mirrored corners, designated pedestrian warning systems and walkways have been implemented, as well as a fully-compliant hi-vis clothing policy. Continuous improvement: Weekly pallet checks, monthly racking checks and risks assessments have been introduced. Vehicle care: To encourage ownership and responsibility for equipment, all fork lift trucks are named – using a Top Gun theme to increase engagement.
Rathcoole premises, John’s new role will be focused on expanding Merlo’s market share in both the construction and agricultural sectors, and in identifying new opportunities for the brand in other areas such as industrial. A parallel responsibility will include sales of Komatsu mini diggers, a role that will see him engage with utilities contractors and plant rental outlets. From Coill Dubh, near Timahoe, County Kildare, John takes up his new position at McHale Plant Sales having previously worked as a service engineer with the company following earlier
connections with Merlo and the plant sector that date back to the mid-1990s.
Bring the iconic WW II aircraft ‘home’
Logistics services company Walker Logistics is undertaking a unique project to commemorate the role that the Berkshire village where it is based played in World War II. Membury Airfield – where Walker Logistics’ 200,000 sq ft multi-user warehouse is located – was the departure point for hundreds of
American troops heading for Normandy to take part in the D-Day landings. One of the few reminders of that history is an image of one of the iconic C-47 aircraft that took off from Membury during the Normandy campaign that features at the front entrance to Walker’s facility. Now a real-life C-47 is being prepared for a return to Membury. The plane was about to be destroyed
at an Arkansas scrap yard in 2012 but has been saved and is currently being restored in the Midlands. “I want to bring it back to ‘base’ once again,” explained Charlie Walker, Walker Logistics’ Customer Relations Director. The plan is to have the aircraft fully restored and back at Membury for the 75th anniversary of D-Day in 2019. And Charlie, who holds a commercial airline pilot’s license, intends to fly the historic aircraft ‘home’ himself. www.handling-network.com
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AUTUMN 2017
viewpoint
Overhead Intelligence
Brian Looby PereGreenEnergy
With energy savings of 60-70% possible from energy efficient LED luminaires, it’s becoming more and more common for industrial premises to retrofit existing light systems and enjoy a relatively quick return on their investment. With outdated lighting systems accounting for a high portion of a company’s annual energy expenditure, energy conscious managers recognise that changes to their existing lighting can have a significant impact on their bottom line. So, with the battle of the bulb veering to one side, what’s next for those seeking to take energy-efficiency to the next level? Attention is now turning to LEDs with controls versus LEDs without controls. So-called smart or intelligent LED lighting solutions elevate lighting efficiencies to a new level. The next generation of wirelessly integrated light fixtures come complete with occupancy sensors, daylight harvesting sensors and a full range of dimming and integrated power metering. These Internet of Things (IoT) -based systems can provide easy access to energy consumption data that can be used to optimize warehouse operations, identify opportunities to improve energy costs, sustainability, and power usage, and drive continued improvements through data. Brian Looby is the founding Director of PereGreen Energy. PereGreen, which provides LED-based lighting services to industrial clients
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and is the official Irish Partner for US smart lighting pioneers, Digital Lumens. The Digital Lumens system offers a specific intelligent lighting solution for Warehouses, Manufacturing, Pharmaceutical and Logistics facilities. “60% or 70% savings from LED is just not good enough, not in this day and age. We need to squeeze every last drop from the system and this is where the controls come in. Intelligent controls can increase savings to over 90% and that’s where we need to be aiming, always,” commented Brian. In addition to yielding up to 90% energy savings, PereGreen’s intelligent lighting installations can generate and yield data that help operations be more productive, use their space more efficiently and manage energy costs across their entire enterprise. “Light is almost a by-product of the system at this stage. As each light fixture has its own integrated sensor, the facility now has hundreds of ‘mini-satellites’ in the ceiling, feeding back information on energy consumption, occupancy, how the facility is operating and where it can improve. This type of information creates smarter buildings and smarter businesses.” Take County Kerry-based O’Carroll Engineering, as an example. This metal fabrication solutions provider operates double shifts out of an 80,000 sq.ft. facility. In 2016, Facility Manager, Declan Lynch identified lighting as a key source of energy consumption and consequently an ideal opportunity for cost reduction. Having considered a number of energy-saving systems, the company identified the Digital Lumens system, supplied through PereGreen Energy Ltd, as the most suitable solution. Working with PereGreen Energy’s electrical team, O’Carroll’s removed 250 existing fluorescent and metal
halide fixtures and replaced them with 116 intelligent LED fixtures. These fixtures are equipped with integrated occupancy sensors and daylight harvesting sensors, as well as metering, reporting and control capabilities. This enabled O’Carroll’s to ‘zone’ certain areas depending on the activity that takes place in that area and tailor the light levels in that zone to suit the activity. In terms of benefits achieved, the project has exceeded initial goals. Throughout the fabrication halls, light levels on the work surface increased by 40% on average, while energy consumption has reduced by 78%. The facilities team can now accurately report their weekly/monthly consumption down to the kWh and euro, as well as occupancy levels in the different areas, an important factor in achieving their sustainability targets. ‘While initially sceptical, this project has demonstrated to us that genuine savings can be achieved through smart energy-efficiency measures. Our advice ... it all starts with smart lighting!’ said Declan Lynch. The entire system comes with a full 10-year warranty, with no limitations on burn hours or switching cycles. Over this warranty period, O’Carroll Engineering expects to save in excess of €160,000 in energy and maintenance costs. “With the savings we are achieving through intelligent lighting, we plan further energy efficient projects to offset onsite consumption of other plant & machinery,” continued Declan. “So, the benefits of this lighting project will continue to be felt for the next 20 or 30 years, which really should be the aim of all energy efficient projects.” Digital Lumen products are registered and qualify under Ireland’s Accelerated Capital Allowance scheme and can help Irish businesses achieve 80-90% savings on their energy consumption costs. This is a tax incentive that allows Irish companies to write off 100% of the purchase value of qualifying energy efficient equipment against their profit in the year of purchase.
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AUTUMN 2017
review
Review - Transport Logistic 2017, Munich Learning to Love Logistics The Transport Logistic event at Munich’s Messe München exhibition centre brings together the people who arrange the transport around the world of just about everything - from the small micro consignments in envelopes and vials, to large deep sea oil platforms.
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Figures for the show highlight the importance of this event. Over the four days in excess of 60,000 visitors passed through the centre’s turnstiles to meet and greet with over 2,162 exhibitors from over 62 countries. All modes of transport - road, rail, sea and air - were represented with a strong showing from allied industries and service providers. In addition, there were 17 national pavilions promoting their own country’s transport and logistics industries. As we in Ireland look to develop new markets, it might be time for us to take a stand. BLUE TREE SYSTEMS Blue Tree’s new management system will set a benchmark in Drivers’ Hours monitoring for the future. The programme has been tested with Irish transport companies and is now being officially launched. See full report soon in Fleet Transport.
www.handling-network.com
COMBILIFT Monaghan based Combilift, the highly-regarded lift truck producer, launched its MR4 model. This multidirectional 360º truck is controlled using a multi-functional joystick, and comes with either sit down or stand up cab options.
AUTUMN 2017
review
seminar on the state of world transport and global logistics. IRU’s Olaf Merk focused on the ‘Big Ship Conundrum’ that arises when bigger ships are built, which means increased capacity reducing transport rates for operators. KRONE TRAILERS Another national brand is Krone, which had one of the larger stands of the event and was constantly busy throughout the opening hours. Interestingly the move into the supply of own branded tyres was one that raised a few eyebrows. TIMOCOM
FAYMONVILLE TRAILERS
Transport Logistic in Munich demonstrated how important vehicle telematics has become and will be well into the future. Telematics giant TimoCom can help to ensure it all goes smoothly with the launch of its new TC Transport Order.
Faymonville, one of the big names in heavy haul specialist trailer production, was part of the Belgian national stand. The trailer brand is well known in Ireland through main dealer Ashbourne Truck Centre. TERBERG
SCHMITZ CARGOBULL Schmitz Cargobull has combined a number of systems to create improved efficiencies. With the new Cargobull App, a driver has full monitoring control of fridge temperature, tyre pressure, and rear door security, all in one.
Terberg is synonymous with the production of Port Terminal tractors, and the Dutch company displayed the Terberg YT 202 EV. This new electric powered yard truck will complete a shift of 9/10 hours on a recharge time of 2/4 hours. IRU
FLEETBOARD FleetBoard is increasing in popularity which means that it must be delivering for operators. The latest incarnation of the Mercedes-Benz system is providing updates on fuel prices, ferry routes and available loads, and is due to come back to Ireland soon.
The International Road transport Union (IRU) delivered an interesting
DKV EURO SERVICE Now far removed from being a simple fuel card system, DKV was promoting its ‘One Box’ system. DKV One Box will enable a single transponder to cover the majority of commercial vehicle toll charges when travelling in Europe. DACHSER SE One of the largest logistics stands was emblazoned with the distinctive blue and yellow of Dachser Logistics. The livery will no doubt become a more familiar sight on the roads of Ireland as the German company is now the majority shareholder in Johnston Logistics. Text & Photos: Paul White
KÖGEL TRAILERS The highlight of the Transport Logistic show for local trailer maker KÖgel was its Euro Trailer Mega Rail which has been extended by 1.3 m to offer a capacity of 37 Euro pallets.
www.handling-network.com
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AUTUMN 2017
safety
FOCUS ON -
Forklift safety in the workplace! Vehicle movements are the single biggest cause of deaths in Irish workplaces. Every year at least 20 people die and hundreds are seriously injured in accidents
THE MOST COMMON TYPES OF INCIDENTS INVOLVING FORKLIFT TRUCKS ARE: Struck by a moving truck
involving moving vehicles.
Struck by a load falling from the truck
The majority of the dead and
Overturn of the truck
injured are pedestrian workers or
Fall from a height
members of the public. Forklifts
Trapped between the mast and overhead guard
are one of the most common vehicles involved in serious workplace accidents. WHAT ARE THE RISKS? Forklifts cause more workplace deaths and injuries than any other piece of equipment. Many of those killed in forklift-related incidents are pedestrians. Even when forklifts are travelling at low speeds they can crush pedestrians. The dangers associated with the use of lift trucks in the workplace are often underestimated. Employees working with or around them often become complacent because lift trucks are quiet, busy, in frequent use and part of the environment. However, incidents involving lift trucks are usually serious and often fatal. Lift trucks are very heavy, even when unloaded and there is very little protection for pedestrians.
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Other less common incidents involve injuries due to fire or explosions, incidents involving replenishing the power source, or unsuitability of the lift truck for the environment.
cages falling off the forklift truck blades (tines) onto a person people being crushed between the forklift truck and structure forklift overturns resulting in operator falling out of cab and being crushed. FURTHER INFORMATION Resources on managing forklift activities at work, including factsheets, videos and online courses can be accessed at http://www.vehiclesatwork. ie or by contacting the Workplace Contact Unit at Lo-Call: 1890 289 389 (between 9.30 am and 12.30 pm, Monday to Friday).
Crush and foot injuries tend to be common injuries suffered by pedestrians. Drivers tend to suffer injuries caused as a result of truck instability, which result in the truck tipping over and crushing the driver.
WORLD LEADER IN PALLET TRANSFER TECHNOLOGY
TYPICALLY DEATHS AND SERIOUS INJURIES INVOLVING FORKLIFT TRUCKS ARE DUE TO: loads falling off the forklift truck onto a person working or walking nearby
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City West 13th September 2017
Here at Combind we are committed to offering our customers an extraordinary blend of value & expertise across a range of packaging and strapping equipment, materials and spare parts, all supported by our technical and after sales service. Our Promise: Be Extraordinary Visit our stand at the Food and Drink Exhibition where we will be exhibiting our Ergonomic range of Strapping and Stretch Wrapping Equipment. Additionally, on stand Q4&5, we will be showcasing the Audion range of Packaging & Sealing Equipment www.audion.com The ERGOPACK Mobile Pallet strapping system allows the operator to strap pallets efficiently without bending and in a safe and upright position with ideal working height. Since 1999 ErgoPack have been the technological experts in the pallet strapping field. A unique range of mobile pallet strapping systems have been developed and manufactured to assist with the health and efficiency of our customers’ logistical processes while redefining the pallet strapping market. To complement our range of ergonomic strapping systems we will be showcasing the new OSCAR Self Propelled Stretch wrapper, by EFFE 3TI. Having successfully distributed Effe’s impressive range of SPINNY Turntable Stretch Wrapping machines we are delighted to add the well sought after Robotic model to our portfolio of reliable packaging equipment. This mobile and flexible model allows the operator to conveniently secure products in multiple locations. As with all machines produced by EFFE 3TI the OSCAR consists of advanced technology that determines the high quality of our stretch wrapping machines together with adequate costs, reduced maintenance and service.
For more information on these or any other products within our range please visit
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AUTUMN 2017
awards
Saluting the best of the UK’s logistics industry At the annual United Kingdom Warehousing Association’s (UKWA) Awards 2017, companies and representatives within the warehousing and third-party logistics (3PL) sectors were rewarded for outstanding performance and professionalism.
The UKWA Awards are established as symbols of achievement in the 3PL sector and emphasise the importance of logistics within today’s economy. This year UKWA received a record number of entries in all categories. A total of 10 UKWA Awards were presented by the event’s celebrity host, Gerald Ratner at London’s Dorchester Hotel. The winners were: BEST NEW UKWA MEMBER OF THE YEAR - DALEPAK LTD This is a corporate award given to the company showing the highest professional standards of warehousing on joining UKWA. This year it was presented to Dalepak Ltd, an omni-channel fulfilment specialist. Based in Northampton within the distribution “golden triangle” of the UK, Dalepak fulfils over 4.3m orders and handles over 186m units each year. JUNIOR MANAGER OF THE YEAR JAMIE CASH, CENTURY LOGISTICS Jamie demonstrated the outstanding personal and professional qualities and leadership potential required to win this category. Stephen Basey-Fisher, MD of Century Logistics, said of Jamie: “Jamie takes a very structured approach to his work, always looking for new and better ways to improve processes and support his team.” WAREHOUSE MANAGER OF THE YEAR - DANIEL EARP, BOUGHEY DISTRIBUTION Daniel was nominated by Boughey’s MD, Keith Forster, who said: “Optimising use of operational resource has been the hallmark of Danny’s leadership, but it is his holistic approach to operations that has brought the most tangible benefits to Boughey’s
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wider business performance. I have watched Danny meet every challenge he has faced head on. His initiative and drive are the reasons why he is succeeding.” ENVIRONMENT AWARD WALKER LOGISTICS LTD The judges were impressed by a number of green initiatives undertaken by Walker. These included dramatically cutting the amount of waste packaging generated by its clients’ supply chains by turning in-bound transit packaging waste into protective void-fill material that is then used to protect outgoing orders. AWARD FOR TECHNICAL INNOVATION - SEC STORAGE WITH INTERNATIONAL LOGISTICS GROUP SEC Storage collected this year’s UKWA Technology & Innovation Award for a bespoke storage solution it designed and installed at UKWA member International Logistics Group Ltd’s new distribution centre. TRAINING AWARD - CENTURY LOGISTICS LTD This award is given for training achievement and can be awarded to an individual, organisation or jointly to both. Century Logistics impressed the judges with its “Project Accelerate” development programme, which aims to provide accredited training for 90% of the company’s employees by the end of 2018. YOUNG EMPLOYEE OF THE YEAR - SCOTT MCCUTCHEON, BULLET EXPRESS Open to any employee not in a supervisory or managerial role under the age of 25, Scott McCutcheon of Bullet Express took the prize.
His passion for and understanding of IT did not go unnoticed and when Bullet moved to a new 200,000 sq ft site, Scott was given the job of managing the software system used to map 21,000 pallet spaces, label the entire warehouse and integrate Wi-Fi and hand-held scanners. CUSTOMER SERVICE AWARD MAXIM LOGISTICS The panel looked for evidence of customer insight and a customer-focused culture within an organisation and were most impressed with Maxim Logistics’ entry. The company’s most recent set of performance statistics were highlighted, notably, ‘justified complaints’ are at 0.08% against a target of 0.15%; ‘warehouse damage’ is 0.046% against a target of 0.5%; and ‘service levels’ are 99.5% against a target of 98.35%. WAREHOUSE COMPANY OF THE YEAR - INTERNATIONAL LOGISTICS GROUP Presented to the company showing the highest professional standards of warehousing on joining UKWA, this year the award went to International Logistics Group. ILG opened three new facilities in 2015/16, while a new flagship site opened in 2017 to provide another 44,000 sq. ft. of warehouse space. CHAIRMAN’S AWARD - STEVE GRANITE, THINK LOGISTICS The UKWA Chairman, Tony Mohan presents this award to an individual or company who has made a real and lasting contribution to the logistics industry. Tony chose Steve Granite, founder of ‘Think Logistics’ as this year’s recipient. Text: Jarlath Sweeney
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AUTUMN 2017
IFOY 2017
ER N N I W
The 2017 ‘International Forklift Truck of the Year’ (IFOY) contest brought together the latest innovations from the materials handling industry eager to be recognised by the prestigious annual honours list. The seven manufacturers nominated included Crown, Jungheinrich, KickTrike, SSI Schafer, Still, Torwege, and Unicarriers. This year’s event had a particular focus on innovations in the areas of safety and automation. Ireland’s representative on the jury is Fleet Transport and sister publication Handling Network. WAREHOUSE TRUCK
Junghenrich’s entry in the Warehouse Truck Category was its EMD 115i, deemed to be the world’s shortest stacker. It targets tailboard deliveries to small shops and businesses, and is a very neat lift-truck to work with. The EMD 115i has exceptional visibility through the mast, greatly enhancing workplace safety particularly if operating in a retail store.
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Scaling New Heights in Warehousing Excellence
lift and lower speeds by 68% and 13% respectively. SPECIAL VEHICLES
Still Group entered its iGo Neo CX20 order picker which follows an operator without the operator having to climb aboard to move the truck. Using a control pad worn as an armband the operator can instruct the unit to move or stop. The IFOY test team found Still’s iGo Neo could produce an improvement in pick efficiency of up to 47%. The other finalist was Unicarriers Group EPH 125 DTFV, a high-lift order picker with operational heights up to 12.1 metres. The unit is designed with a Pro-Access gate to allow operation without the gate being closed at lower levels. In addition, Unicarriers has improved driving speeds by 42%, and
In this category Crown entered WAV 60. While the WAV 60 is not a lift truck in the traditional sense, this style of work platform and order picker has a lot to offer businesses. WAV 60 will appeal to companies in warehousing and retail. It is also extremely useful as a mobile ladder for a range of maintenance tasks. The second nominee, KickTrike, will transport packages weighing around 50 kgs. KickTrike can achieve speeds from 6 to 25 kp/h and depending on the
AUTUMN 2017
IFOY 2017
mode selected (Eco, Tour & Boost) the range of the 48-volt lithium-ion battery (1.4 kWh) is approximately 50 kms.
or other items and does so with a high degree of self-learning.
throughout the work area. For heavy duty electric trucks, high battery temperatures are always a problem. Still has developed a solution which it claims significantly increases battery life. The self-cooling PowerPlusLife battery will reduce operating temperature by up to 20°C and can extend battery life by up to two years.
SPECIAL OF THE YEAR Also in this category was Still’s Tugger Train, for loads of up to 2.5 tonnes. Using a blue arrow projected onto the floor, the driver positions the C frame alongside the appointed location. Once aligned, Tugger Train will automatically drop or pick as directed. All instructions are given through a touch screen in the cab. AUTOMATED GUIDED VEHICLE (AGV)
Two AGV nominations were selected for the final. The first was 2Stack from SSI Schafer which uses a guided racking system to replenish orders when stock items fall below a pre-determined level. Once the order has been received, delivery of the racking is guided by lasers to ensure accurate positioning. The other nomination was Torwegge’s TORsten. What makes TORsten novel for an AGV is it’s omnidirectional abilities. The construction of TORsten is robust and this specification is capable of lifting up to 1,200 kgs. Versions for heavier applications can offer a lift capacity of up to 7 tonnes. TORsten can transport pallets, trollies
Jungheinrich’s entry for Special of the Year was a truck finder system that not only identifies where any truck is currently positioned but it can also analyse where all the trucks have been. Indoor Positioning can provide important data regarding traffic flows and work-patterns. Each truck is equipped with a smart phone and the
Safety was the focus of the Unicarriers entrant. A simple yet effective floor activation device uses the whole footplate as the sensor. Unicarriers believes this is preferable to a driver constantly applying pressure with one foot to activate a button or switch. The 2017 IFOY winners were announced to a gathering of over 200 invited guests and dignitaries at the ‘BMW World’ building in Munich, Germany. In her address, the Executive Chairperson of the IFoY Jury, Anita Wurmser, said “Industry 4.0 is fast becoming part and parcel of intralogistics. This is an area in which the winners have showcased innovations that not only promise but also measurably supply quantum leaps in terms of customer benefit.” Text: Paul White
IFOY 2017 AWARDS CATERGORY
WINNER
AGV Shuffle
Torwegge TORsten
Warehouse Truck Still iGo Neo CX20 Special Vehicle
Still Tugger Train
Special of the Year Jungheinrich Indoor Positioning System
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case study CASE STUDIES
An Post delivers more with new ePOD An Post has boosted its offerings and increased functionality by upgrading its electronic proof of delivery (ePOD) system to ZetesChronos.
Photo accreditation – An Post
With some 1.7 million customers, the company wanted to offer a more comprehensive range of services and delivery options. ePOD is typically a signature from the recipient of a parcel input directly into a portable device, held by the delivery person, and automatically entered into the IT system. This helps to make the process safer, less liable to be taken advantage of, and easier to spot and solve delivery problems. The growth of e-commerce has made this a significant development, with more and more parcels delivered each year. ZetesChronos is powered by the MCL Mobility Platform and will run on the Honeywell devices already used by the firm. “Zetes offered us a highly agile solution, which meant that we didn’t need to upgrade our current
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devices,” said Liam O’Sullivan, Director of Mails Operations at An Post. “This ensured that we were able to maximise our original IT investment. With around 4,600 postmen and women in the field, being able to centrally manage and deploy our applications from a single platform is also a true game changer; saving us valuable time and resource.” The new software provides better customer interaction and more streamlined management of inbound shipments. It will allow An Post to add apps and other systems as its business evolves. An Post can now easily add new services and products to its apps, enabling it to react quickly to market or customer changes. It will also have the ability to centrally run, deploy and manage applications, without the need for costly IT infrastructure or to make alterations to its underlying software. The handling of inbound shipments coming from other companies will also be improved with a new automated receipting system. An Post has been working with Zetes for over 15 years to streamline its supply chain processes. Two solutions of Zetes’
Collaborative Supply Chain Suite have already been successfully taken on and rolled out by the semi-State company. The ZetesOlympus traceability solution runs in An Post’s sortation centres to track all items. This means monitoring up to 2.5 million items of mail each week, from the moment they enter the An Post network through to customer signature capture. In addition, An Post also uses the ZetesAres field mobility solution, also powered by the MCL Mobility Platform, to enable real-time data capture and
visibility for its 70 inspectors investigating unpaid TV licence fees on behalf of the Irish Government. Zetes will continue to provide complete managed services to An Post. This includes end-user support, next day exchange and maintenance of the devices, Remote Device Management, Application Support and IT Service Management, as well as on-site preventative maintenance visits to ensure every device is kept operational. Alain Wirtz, CEO of Zetes added: “As with many of the postal companies we collaborate with, An Post is continually looking for new ways to offer competitive services. We are proud that it continues to see us as a trusted partner and allows us to help future-proof its business.”
AUTUMN 2017
case study CASE STUDIES
Cimcorp automates new tyre factory Algerian consumer electronics and household appliances group Saterex has selected Cimcorp to design, manufacture and install an automated handling system for its brand new tyre factory. Under its ‘Iris’ brand, Saterex is a leading supplier of electronic, IT and household appliance products including TVs, satellite receivers, DVD/ Blu Ray players, washing machines, fridges, freezers, microwave ovens, cookers, smartphones, tablets, computers, air conditioning units and heaters. The company currently employs almost 1,200 people across six production sites in Algeria. With huge growth in sales of its Iris products, Saterex is now diversifying into tyre manufacture. The new plant is being built in Sétif, 300 km east of Algiers, and will be the first tyre factory in Algeria since Michelin Group closed its plant in the capital in 2013. Managing Director of Saterex, Yacine Guidoum, said “The area around Sétif is undergoing significant economic growth across a number of sectors, including the automotive industry. The Algerian market consumes more than seven million tyres a year and the products currently imported are generally of poor quality. This represents a fantastic opportunity, to repeat our manufacturing success in another sector. As well as producing locally-branded tyres to meet Algerian demand, we will be exporting about a third of our output to European and
African markets.” The new facility will be the largest tyre manufacturing plant in Africa, and will be operational by Spring 2018. It is expected to produce around one million passenger car radial (PCR) tyres in its first year, followed by two million units of both PCR and truck and bus tyres in the second year. “With this being a greenfield site we had the opportunity to design the most efficient factory from scratch” explained Yacine. “This is why we have chosen robotic automation from Cimcorp; we wanted the best logistics technology currently available for our new plant.” Cimcorp has been taken on to supply automated handling systems from its “Dream Factory” solution for both upstream and downstream manufacturing processes at the Sétif plant. This means automated handling from the raw materials and compound warehouse to the mixing and compounding areas, as well as handling automation for green tyres from tyre building to curing, and finished tyre handling in the testing and palletising areas. Cimcorp Group is part of Murata Machinery, Ltd., also known as Muratec. It is a global supplier of
automation for intralogistics, using advanced robotics and software technologies. As well as being a manufacturer and integrator of material handling systems for the tyre industry, Cimcorp has developed unique robotic solutions for order fulfilment and storage that are being used in the food and beverage, retail, e-commerce, fast-moving consumer goods (FMCG) and postal services sectors. With locations in Finland, Canada and the United States, the group has around 400 employees and has delivered over 2,500 logistics automation solutions. Kai Tuomisaari, Vice President, Sales for Cimcorp, said: “We are delighted to be helping Saterex to develop this new tire plant in Algeria. The company’s track record of success in fast-changing sectors demonstrates that it is very forward-looking; this vision has helped Saterex to see the many benefits that flow from investment in Cimcorp’s Dream Factory solution.”
Text: Johanna Parsons
www.handling-network.com
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logistics
E-commerce inspiration Enormous customer demand is focussing attention on the logistics systems that enable e-commerce.
Palletising robots by Swisslog
The continued success of e-commerce is driving massive innovation for logistics. British consumers are spending £1 billion online per week according to the March 2017 figures from the UK’s Office of National Statistics. And it’s not just the commercial rewards but also the consequences of supply chain errors that is focussing attention on optimising handling operations. So it should come as no surprise that the warehouse technology and automation equipment on offer is becoming ever more advanced. The Warehouse Management System firm Peoplevox recently published “The 2017 E-Commerce Fulfilment Report” which found sales had increased in 2016 for 82% of the e-commerce and multichannel businesses taking part. Furthermore, despite concerns over increasing competition, Brexit, and currency fluctuations, 88% expected a further increase in orders during 2017. However, only 53% of respondents said they were happy with their fulfilment processes and warehouse operations. 63% said they do not always ship on time, and 1 in 5 admitted to not even knowing the cost of their shipping mistakes. Jonathan Bellwood, Founder & Chief Executive of Peoplevox commented: “While it is encouraging to see so many survey respondents reporting continuing sales growth, which is broadly in line with figures for the online retailing sector as a whole, our report has identified a number of growing pains. These will become increasingly challenging for businesses as they continue to expand rapidly.”
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Jonathan Bellwood, Peoplevox CEO
“First and foremost, in this super-competitive era of e-commerce, fulfilment retailers can no longer afford to paper over the cracks. With expectations of next day/same day delivery, customers just won’t accept the apparent inability of online businesses to accurately ship on time, every time, or inadvertently sell items that just aren’t available.” Naturally Peoplevox espouses the virtues of a good WMS, and there’s no denying that proper IT systems are essential for efficient running of any warehouse with any degree of complexity. And while all operations will benefit from greater stock visibility, the pressure is particularly acute for e-commerce, operators. “In e-commerce, we’re all looking to turn our buyers into repeat buyers,” added Matthew Robertson, Co-CEO of NetDespatch. “The goods must be delivered in one piece, on time, with all the right things in the parcel, and that’s just the minimum required. If things
go wrong you need to be awesome at resolving the issue, which is also a great opportunity to build trust. If you really want to get the next order you then need to do a bit more.” Matthew believes e-commerce needs to offer a retail experience that elevates the brand, controls and monitors customer journeys, while managing data at every point in the buying process. “We’re working with businesses to try and achieve this goal and make the e-commerce experience as seamless as possible to meet the ever growing consumer demands,” he said. Meeting those consumer demands is the big driver behind the vast array of IT and automation now on offer to make warehouses more efficient. It is also making people think differently. Jungheinrich, the firm perhaps best known for its forklifts, recently won a “Best Online Shop” award for IT it developed for e-commerce. PROFISHOP is a portal that acts as an online shop for factory equipment. Stefan Wissler, Head of Online Retailing at the Jungheinrich Group, said: “Winning the Swiss E-Commerce Award after such a short period of time proves our market launch was a success. For us, the award is above all confirmation of the fact that investing
Beumer returns handling
AUTUMN 2017
logistics in user-friendly, top-of-the-line web shopping technology does indeed pay off.” John Boulter, Managing Director of DHL Supply Chain Retail UK & Ireland said that the e-commerce pattern for more smaller-pick orders from a wider variety of stock is a major influence on the popularity of automated systems. “We’re seeing businesses – in particular in the retail sector – investing in automated storage and retrieval systems to hold and automatically move pallets according to requirement. Meanwhile semi-automated cranes, robotic shuttles, automated mini-load and sortation systems, and auto packing are just some of the ‘traditional’ modular solutions which DHL provides its customers to allow them to benefit from automation,” said John.
Simon Cooper, Dematic
Simon Cooper of automation firm Dematic Northern Europe reports that the volume of e-consumers and their levels of expectation mean that the need for speed is now extreme. That’s pushing innovation in new directions. “Many retailers are aiming for 15
Dematic robotic picker
minutes from click to ship,” he said. An ambitious target that he reckons can only be achieved by the latest must-have kit: Robots. It might sound like a gimmick but robotised picking and palletising are well established for larger distribution centres (DCs) and the technology is getting quicker and cheaper every year which means it is becoming more accessible. “There is already evidence of a growing number of retail businesses with large manual operations looking to the viability of automated DCs that incorporate robotic systems. Even organisations that presently use paper pick lists are exploring automation,” commented Simon. Brian Whale, Senior Logistics Consultant at automation firm
Swisslog agrees that the demands of e-commerce are making robotics a viable reality for more and more businesses. “Robots offer round the clock automated picking of a range of different products,” he advised. “There’s huge potential to save costs, as, for example increasing from a two to a three shift operation does not require additional investment; the robot does not ‘go sick’ or require holidays and does not need regular breaks,” emphasised Brian. This links in to another finding of the Peoplevox research, that 78% of e-commerce businesses said staffing for order peaks is an ongoing problem. “Of course there are other benefits related to picking accuracy, operating data and the ability to maximise floor space, as well as integration with other parts of the supply chain, but the labour cost savings tend to be the first that spring to most logisticians’ minds,” explained Brian. And the price is no longer as restrictive as you might think. DHL’s John pointed out that the return on investment for a full scale integrated automation project can take up to six or seven years, “Meanwhile more tactical and stand-alone automated solutions, such as collaborative robots, can pay back in as little as 18 months.” So from IT to robots and every flavour of automated system in between, you can thank the success of e-commerce for driving the development of all these shiny new options. And they are probably available to buy online too.
Text: Johanna Parsons
Collaborative Picking Robot from Swisslog www.handling-network.com
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supply chain
Digital technology will change Supply Chains beyond recognition
In the course of the Multimodal break-out group discussion during the IEA Supply Chain event which took place at the Radisson Hotel Little Island, Cork on 15 June last, Michael Connolly, Sales Manager at Eucon Containers spoke about the company’s recently launched Mobile App. Eucon is the first short sea carrier on the Irish Sea to make a dynamic app available to its customers. “In today’s fast-moving world the smart phone or tablet has become an essential tool in the logistics business. It is unique that we can offer via the app immediate access to our shipping schedules and real-time track and trace of your shipments,” he said. Michael went on to explain that Eucon expects that the provision of real-time information will enable shippers to feel confident about the status and state of their shipment and to accurately plan the final delivery and use of the cargo. What surprised him was the fairly low take-up rate for the app in the period since its launch. When you consider that for most people managing their banking, travel, shopping etc. on the internet is now the norm, one would think that the low take-up of the app is a surprise. However, as the World Economic Forum (WEF) has pointed out in its recent “Delivering change: digital transformation in logistics” document, the Supply Chain sector has been very slow
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to make any fundamental changes in the way in which it operates until now. It is almost 200 years since cargoes of tea were loaded aboard Clipper Ships in Shanghai and sailed to London; now the tea is in containers, the route is shorter due to the Suez Canal and the ships are a little quicker, but otherwise very little has changed. Perhaps the most obvious area for change is in the documentation surrounding the shipment. One analyst who collected together all of the documentation that surrounds a shipment, such as that describing and underlying the Bill of Lading, showed that the paper trail was a 10-inch-high stack. Clearly such a mound of documents is very costly to produce and almost certainly contains a number of errors, correction of which will slow down the planned delivery schedule. It is here that blockchain would come into the picture. A blockchain is a specific type of database where time-stamped and authenticated digital records are compiled. Data added to a blockchain by a party cannot be changed by any other party, and data compiled in the blockchain is added and verified by multiple parties. In a typical supply chain, currently there are dozens of individual parties, each responsible for contributing critical pieces of data associated with a single shipment. If each item of data is submitted by the generator to the blockchain for the shipment, it only happens once and must be consistent with the rest of the blockchain. A PWC report noted: “Logistics solutions based on blockchain technology are developed by start-ups
and gain momentum in areas such as digitized trade documents, chain of custody, customs clearance and trade finance” - such blockchains would significantly reduce costs and risks in the supply chain. The power that use of the internet gives individuals and companies to operate outside the normal trading models becomes more significant each day. The WEF predicts that internet shopping will rise from 7% of global value to 24% by 2025. It goes on to say that not only will autonomous trucks and drones play a significant role in deliveries by then, but that an “Uber” trucking model could decimate the current ‘white-van’ local delivery model, with blockchain based systems simplifying import-export processes, taking out jobs in the traditional freight forwarding sectors. For the dominant players in the freight industry, IT (Information Technology) will therefore be their core competence and not transport. The WEF concludes; “The greatest impact from digital transformation in the logistics industry will, however, come from the societal benefits. These include lower carbon emissions, less traffic congestion, lives saved through reduction in accidents, an increase in cross-border trade as a result of platforms simplifying trade, and discounts to customers on account of increased utilization levels.” It looks as if supply chains will become stronger and lighter, challenging the old order. Text: Howard Knott
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