Material Handling Network's annual Warehouse Solutions insert - September 2019

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September 2019

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September 2019

Warehouse Solutions Insert n 3

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September 2019

5 Ways Warehouse Automation is a Win for Workers When people hear the words “warehouse automation,� they tend to think of lost jobs and a robotic workforce. That is simply not the case.

For warehouse automation to be effective and efficient, human workers must be prioritized and recognized for the vital leadership role they play in the warehouse environment. In fact, an automated warehouse can make for more successful and happier employees.

As more industrial workplaces and warehouses look into the benefits of automation, some of the biggest perks are seen in the outcomes for workers.

Here are five ways that warehouse automation is a win for the workforce.

September 2019

1. Improved Safety Unfortunately, workplace accidents can happen. According to the Occupational Health and Safety Administration (OSHA), fatal incidents occur more frequently in the warehouse setting than in other workplaces.

Some common hazards include forklift mishaps, improper stacking of pallets, failure to use proper safety equipment and failure to follow proper safety procedures.

But one of the key benefits of automation is improved safety for the human worker. A robotics solution, including robotic forklifts, takes people out of harm’s way on the job.

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While it might be costly if an automated robot was damaged on the job, it is nothing compared to physical and emotional toll a human incident could take on your company.

2. Quality Over Quantity Speaking of workplace injury, one of the most common injuries on the job come from repetitive motion. Constantly lifting, stacking or sorting for 40 hours a week can do serious harm to the human body.

With an automated warehouse, many of these repetitive tasks can be given to machines or robotics. This frees up human workers to focus on more innovative and enjoyable value-added tasks. And because an automated solution is often capable of doing repetitive jobs faster and more efficiently, this can be great for productivity as well as workforce morale.

3. Save More Jobs It has actually been proven that warehouse automation can keep jobs from being displaced and therefore improve the layoff rate. According to Entrepreneur, major companies such as Evian, Accenture and Boxed saw zero layoffs following a robust automation initiative. Some even added to their workforce. How is this possible?

Because the automation solutions were used to empower the workforce. The various robotics solutions worked alongside and for the human employees, helping them do their jobs more efficiently and effectively. When employees are productive, get to do work they enjoy and are learning new skills (in this case robotics), they are happier and more fulfilled in their jobs.

4. Turn a Job Into a Career With automated warehouse technology taking over the menial, repetitive tasks of traditional warehouses, the role of humans in the warehouse is changing. One of the primary perks of an automated warehouse is

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that people get to learn new, highly valued skills. What was at first a job with minimal room for growth can transform into a lifelong career.

5. Reinvest in the Workforce Yes, warehouse automation will require an investment. But it is also an investment in your operations, efficiencies and the future of your company. Many warehouses that invest in automation technologies see ROI in 12 months or less. With that added revenue, companies and warehouses can invest in the growth and professional development of their workers.

A McKinsey report showed that 62% of executives said they will have to retrain or replace 25% of their workforce by 2021 to work alongside automated processes. Finding that many well-trained workers would be nearly impossible, and companies are seeing the value in training their current workforce to use the robotics and automation technologies.

They already know the business, the workflows, and are well versed in the product.

While estimating significant worldwide “productivity growth from automation” in the coming decades, the same McKinsey report also states the simple truth about warehouse automation – “Humans will still be needed in the workforce: the total productivity gains we estimate will only come about if people work alongside machines.

That in turn will fundamentally alter the workplace, requiring a new degree of cooperation between workers and technology.”

Evan Hammersley is the Warehouse Automation and Robotics product manager for NITCO. After leaving the Army in 2018 he joined NITCO and has become an expert in Automation and Robotics.

He is experienced in all aspects of robotics and automation, working with both dealers and manufacturers, giving him a unique perspective on the industry.

When not working, Evan is pursuing his MBA and enjoys lacrosse and hockey during his free time.

Email: Networkeditorial@wcinet.com

September 2019

West Point Rack “We don’t just promise…we deliver!”

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Cantilever Racks • Structural Pallet Racks Portable Stacking Racks Specialty Transport & Storage Products West Point Rack is one of the fastest growing companies in the industry. Our customers recognize quality products, dependability of service and competitive pricing.

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Our Primary Goal is to support our dealers, satisfy their customers, earn trust and be the “Vendor of Choice” for rack products and racking systems.

We offer a full line of light duty, intermediate duty, heavy and extra heavy duty cantilever racks. We provide multiple configurations of a wide variety of stacking racks. Our structural pallet racks can be configured for a wide range of applications.

West Point Rack has the products that generates solutions for your storage needs.

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Warehouse Solutions Insert n 7

Industry 4.0: Warehouse Solutions Fit for the Future Today’s warehouses and distribution centers are facing unprecedented challenges in their operations.

They now have to work harder and faster to keep up with the speed of fulfillment expected by the modern consumer. These consumers—a large segment of which are millennials—have grown accustomed to the e-commerce experience, where they can get exactly what they want and when they want it. This places significant pressure on distribution centers to maximize efficiency and maintain order accuracy.

Moreover, many facilities now have to accommodate a growing number of SKUs, as manufacturers continue to expand their product offerings in response to consumer demand for variety. Organizations must thereby find ways to better utilize their existing storage space or budget

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for new construction.

These modern challenges require modern solutions. Warehouses and distribution centers must adapt, especially as other areas in the supply chain embrace the next generation of technology at the intersection of robotics, computers and the Internet of Things (IoT). Collectively, these technologies make up the fourth Industrial Revolution, also known as “Industry 4.0.”

Industry 4.0—where robots, computers and the IoT meet The first Industrial Revolution emerged out of the dawn of mechanization and advent of the steam engine. The second was powered by electricity and the invention of electric motors, enabling the mass

September 2019

production of goods. In more recent years, microchips and computers led the third Industrial Revolution, which saw an increase in processing capacity in society and industry.

Now, the fourth—Industry 4.0—sees robots, computers and the IoT converging to create new cyberphysical environments, where companies can use automation to speed and scale up repeatable tasks, as well as use sensors to capture data on what these automated tools are doing and how they are performing.

Businesses can then take the captured data to find ways to improve processes or reorganize automation in real time. Industry 4.0 is creating more data-driven enterprises with the ability to pivot and innovate as needed. It is set to disrupt virtually every industry, including warehousing and logistics.

The new cyberphysical distribution center In the modern cyberphysical environment, distribution centers can control as well as track and trace products from receiving, through storage and all the way to outbound shipping. Two networks make up the cyberphysical environment: the physical network of robotics and hardware and the cyber network that ties everything together through data.

• The physical network—nuts and bolts The physical network of automated systems includes automated guided vehicles (AGVs), mobile robots, gantry robots, articulated robots, monorail transfers, automated storage and retrieval systems (AS/RS), conveyors, etc. These systems can move products between receiving, storage, preparation and loading with high precision and accuracy.

Notably, using high-density storage and an AS/RS, facilities can house more products in up to 50 percent less space, which can help solve for SKU proliferation. And thanks to the speed of robotics, they can implement just-in-time order picking and prepare goods for outbound shipping within minutes of a truck’s arrival. This minimizes the space needed for preparing orders and truck turnaround times. All hardware is

September 2019

outfitted with barcode readers, vision systems, laser scanners or other technologies that collect and send sensory data to software in the cyber network.

• The cyber network—the seamless flow of data In the Industry 4.0 distribution center, all automated equipment and subsystems are integrated with internet-connected systems that can assess and control performance. For instance, Warehouse Control Systems (WCSs) can capture real-time sensory data that users can then leverage to guide the movement of warehouse automation for optimized intralogistics, inventory management and productivity.

With the right combination of automated technology, sensors and advanced control systems, distribution centers can capture data to better understand their processes, run analyses and use the results to improve material flow.

They can thus have total control over their products in inventory, and readily accommodate changes to an individual order or demand in the market as a whole.

The future of distribution, available now All this talk about cyberphysical systems and realtime data flow may sound like a far-off pipe dream.

In truth, companies can start taking steps towards bringing their facilities up to par with Industry 4.0 by using a modular approach that gradually scales up technology investments by installing automation in phased implementations.

Many of these technologies can fit into existing operations as “islands of automation.” Warehouses and distribution centers can then introduce more robotics and software over time. A phased approach makes modernization easier to manage, keeps costs low and delivers quick returns on investment, while edging companies closer towards the automated, data-driven distribution center of the future.

Written by: By Derek Rickard, Sales Manager, Cimcorp (http://cimcorp.com/). Email: Networkeditorial@wcinet.com

Warehouse Solutions Insert n 9

Forklift Academy created affordable forklift certification solutions for companies and individuals to comply with OSHA Rules and Regulations. Our training solutions include convenient online training, in person training at our training centers, on-site training at your location, and a master trainer’s kit for companies to establish and run their own program effortlessly.

Our mission is to improve safety awareness for companies by providing effective and practical forklift training to ensure compliance with Federal regulations and to help companies avoid penalties and expenses associated with OSHA inspections.

The company has been in the safety business for fifteen years helping companies with their safety needs. Our main office is centrally located in Southern California, with several locations throughout the US including Texas, Florida, Georgia, etc. Our qualified trainers cover the rest of the country on a regular basis.

Our main goal is to provide comprehensive, effective, and affordable forklift safety training to help companies comply with Federal and State Laws

Locations in LA, Houston, Atlanta, Miami, Reno, Dallas, Bakersfield, San Diego.

(877) 388-3239 WWW.FORKLIFTACADEMY.COM 10 n Warehouse Solutions Insert

September 2019

ON-LINE TRAINING

The Occupational Safety and Health Act of 1970 includes a provision that states, “only trained and authorized operators will be permitted to operate a powered industrial truck.” The 1-2 hour online forklift evaluation training course will allow you to become a certified forklift operator in compliance with OSHA laws.

US TRAINING CENTERS

Forklift Academy offers classroom training in business markets around the United States. This classroom training is designed to help get your staff the safety training certification they need to be OSHA compliant. Our experienced trainers help ensure your operators are fully safety trained and complete the coursework and testing required for their forklift certifications. Forklift Certification training are OSHA accepted and valid for 3 years.

ON-SITE TRAINING

The Forklift Academy offers private, on-site training designed to help you get your staff the safety training certification they need to be OSHA compliant. Our experienced trainers can help ensure your operators are fully safety trained and complete the coursework and testing required for their forklift certification. The Price will depend on the number of people (more people more affordable), and location. We have qualified instructors across the USA ready to travel to your job site. Our Forklift Certification training are OSHA accepted and valid for 3 years.

TRAIN THE TRAINER

Complete OSHA Compliance Forklift Certification training kit includes, a CD power point presentation, FREE Forklift Operator Training Video, instructor guide, new OSHA regulation, forklift compliance and operator guide, daily inspection checklist, attendance sheet, written & driving tests, certificates (20), and wallet cards (20).

Locations in LA, Houston, Atlanta, Miami, Reno, Dallas, Bakersfield, San Diego.

(877) 388-3239 WWW.FORKLIFTACADEMY.COM September 2019

Warehouse Solutions Insert n 11

Advantages of Pneumatic Vs. Electric Hoists Why air hoists are beyond compare for safe, reliable, cost-effective lifting.

When considering a new investment in hoist technology, a full comparison between pneumatic and electric hoists can pay real dividends. In short, pneumatic hoists offer numerous advantages over their electric counterparts. In areas such as duty cycle, variable speed control, weatherproofing, installation and operation, maintenance, robustness, investment costs, lifetime costs and of course safety, a pneumatic hoist really makes a difference.

Duty cycle is amongst others an important area of focus. Electric drives can only be used for intermittent operations (S2 duty), so are not suitable for continuous use. Conversely, pneumatic hoists have no downtime and a 100% duty cycle rating. In addition, pneumatic hoists can work constantly without causing excessive temperatures. This of course offers a great benefit to end users as hoists can be in uninterrupted use over multiple shifts.

With regard to variable speed, a pneumatically operated hoist is able to offer easy, accurate and wide-ranging speed control at low cost, enabling simple, sensitive and accurate positioning of loads in all environmental conditions. In comparison, an electric hoist will require a frequency converter (also known as a VFD) and shielded wires to prevent radio interference, while the motor will need thermo-elements to avoid increased heating at the windings.

Clearly, safety becomes a major issue for electric hoists in potentially explosive environments such as oil rigs, mines and paint shops. Moreover, it is challenging to configure electric drives for use in such areas, at least not without considerable cost. In contrast, there are no such issues when using air-operated hoists. By using compressed air as the driving media, they are suitable for use within dust laden atmospheres, including areas at risk of explosion and even where organically flammable chemicals are in use.

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Of course, if the hoist is intended for outdoor use, the whole issue of weatherproofing arises. Using an electric hoist for such an application means careful selection based on its IP protection class rating, which denotes its ability to resist the ingress of solids and moisture. Needless to say, there are no such issues with pneumatic hoists which, as non-electric equipment, are not subject to the IP rating system. Any contaminants such as dirt or water are simply blown out by air without any compromise to functionality. This is also crucial in areas where hoists need to be cleaned at regular intervals or within humid environments, such as the food industry.

Pneumatic hoists are low in weight compared with their electric counterparts, making them more mobile and far easier to handle. Not that this factor compromises operational strength, as air hoists are ideal for performing large lifting heights, providing true vertical lift without any limitation in the number of starts/stops per hour. The simplicity of pneumatic hoist technology also lends itself to easier installation compared to electric hoists which require qualified personnel.

Pneumatic hoists contain relatively few mechanical components compared to electric hoists and fewer components means less to go wrong.

Finally, when comparing the cost of pneumatic and electric hoists, many factors must be considered beyond the price tag, including installation, operation, inspection and maintenance costs. Upon performing this TCO (Total Cost of Ownership) calculation, the economic advantages of pneumatic hoists quickly become apparent.

Company Information:Â J D Neuhaus manufactures pneumatically and hydraulically-operated hoists and crane systems up to 115 ton capacity from its state-ofthe-art facility in Witten, Germany. J D Neuhaus has set the quality standard for the market and their products offer solutions to almost every material handling problem. www.jdngroup.com Email: Networkeditorial@wcinet.com

September 2019

PRODUCT PREVIEW

Vestil - Economy Electric Pallet Truck Best-value electric pallet truck with reduced cost is a perfect alternate to manual hand pallet jack. Compact body design with light service weight (weight is half compared to traditional EPT) and small turning radius (only 1¼” longer than standard EPT and 6-10” shorter than traditional EPT) allows this truck suitable to use in tight areas, low duty applications, supermarkets, grocery stores, logistic centers, and warehouses.

Multi- function ergonomic handle with Emergency reverse, battery indicator, raise-lower buttons, horn and forward-reverse butterfly switch. Long Tiller handle reduces fatigue. Handle returns to vertical position automatically when released. All parts are easily accessible and easy to maintain. www.vestil.com

ShipWorks for WarehouseTM ShipWorks for Warehouse includes the automation features and rapid label print speeds of ShipWorks’ desktop-based e-commerce offering, along with Open Database Connectivity (ODBC); access to ShipWorks HubTM for web-based order management, support for fulfilling orders from multiple sites with intelligent order routing, and business intelligence; and scan & pack quality control. “ShipWorks is building on its nearly twenty years of experience in shipping to launch its new ShipWorks for Warehouse product offering, tailored for high-volume shippers,” said Dominic Lozano, General Manager of ShipWorks. www.shipworks.com

Warehouse Striping Industrial line marking is the dualpurpose product used in distribution centers. Firstly, internal floor marking is used to improve storage efficiency by clearly designating areas. Secondly, it is used for safety in demarcation for pedestrian access routes, forklift truck aisles and no-go-zones, all critical guides to separation without complete restriction. ASG Services for many years, have led the way in marking technology, through concrete preparation, floor coating materials and application methods. In all this, durability and a cost-effective approach have been fundamental factors. www.asgservices.com

September 2019

AMR Flow Rack Replenishing StackerBot Robot The Stacker-Bot can store and retrieve on a single trip up to five cases or totes. It can retrieve inventory from the floor, shelf or a conveyor level. It automatically picks a case or tote, scans the barcode and stores it in the StackerBot on any of the five on board shelves. It then uses its RCS (robot control system) and communicates to the WMS/WCS host software system. Once up to five totes or cartons have been retrieved in the Stacker-Bot, it is directed via the WMS/ WES software host the exact locations required to place the inventory. The robot always travels via the shortest path to its put-away location. www.conveyco.com

Slit Coil Storage Racks

Rack Engineering Division, a manufacturer of custom storage and material handling products specifically designed for high weight capacities and heavy use, today released information about their Slit Coil Storage Racks. These Slit Coil Storage Racks come in various sizes and versions including stationary, mobile and portable. Each unit provides optional rubber runners for additional material protection when required. The removable adjustable pins allow the unit to adjust between various coil widths. Rack Engineering units are custom produced to meet the customers exact sizing requirements. www.rack-eng.com

Cimcorp MultiPick

The Cimcorp MultiPick is a robotic materials handling solution that precisely controls and streamlines the entire material flow of a distribution center or dispatch area. By design, MultiPick combines buffer storage and order picking into one seamless operation. It can handle a variety of standard crates, bins and trays with rapid speed, 100-percent accuracy, optimal use of space, easy cleaning and improved labor savings. Any number of robots—each equipped with grippers designed to handle a particular unit load—can be implemented and tailored to the throughput demands of each facility. As product and/or order volumes grow due to demand or seasonality, warehouses can extend and scale up their number of robots as needed. www.cimcorp.com Warehouse Solutions Insert n 13

ADVERTORIAL

Static Charges: An overlooked hazard in forklift operations If you ever shuffled across a carpeted floor in your socks and then felt a little “zap” when you touched a metal doorknob, you’ve experienced the shocking effect of static buildup.

Now imagine a static charge that builds up to as much as 50,000 V, and you start to appreciate the hazards that many forklift operators face every day.

Static BuildUp Static electricity is generated when two dissimilar materials are rubbed together. Insulating materials, such as rubber, are the most prone to accumulating static until it makes contact with a more conductive material. Forklifts using black tires generate static but they’re continuously releasing their potential charge because of the carbon black – a conductive material.

The problem with non-marking tires Some applications, however, require non-marking tires: Forklifts that operate indoors, on warehouse floors with light-coloured coating and surface finish or in food processing plants, for instance, are often fitted with non-marking tires.

Non-marking tires don’t have this anti-static property since they contain silica in place of carbon black. Where carbon black is conductive, silica is an insulator. As a result, static generated in the tires is stored rather than dissipated. The static continues to build up in the forklift to potentially hazardous levels – enough to spark up a fire in the truck, to wipe out electronic circuits, or to knock down a person who inadvertently touches the equipment.

NEW

Makeshift solutions The industry has tried makeshift methods of dealing with problematic static. Some forklift operators will attempt, among other things, to ground the vehicle by raising the forks or attachment, and slamming it onto the floor. But grounding the attachment does generally not ground the accumulated electricity, no matter how hard you hit it.

More commonly, users will attach chains or grounding straps under the truck. But again, their effectiveness is limited. Drivetrains are still insulated from the frame by rubber mounts and bushings. Meantime, the straps and chains tend to gather dust and debris over time that gradually insulates them from the ground, wear down or break off.

Solving it at the source

Like most safety issues, the solution to hazards of static electricity must be addressed at multiple levels. The real opportunity for safety is in the hands of tire manufacturers to respond with a new solution. Specialized anti-static tires are available for certain applications, but there have been no non-marking anti-static (NMAS) tires available until just this year.

Extensive research and testing has led Camso to come up with a true breakthrough in tire design with the launch of the first patented anti-static forklift tire to resolve the important safety issue of static electricity generated by non-marking tires. Indeed, the Solideal PON 775 NMAS provides a solution to an existing problem that had never really been addressed before.

The world’s first tire to prevent static build-up SOLIDEAL PON 775 NMAS BY CAMSO This innovative press-on tire solves the issue of static build-up generated by non-marking tires, by continuously grounding the truck through the tires thanks to its patented anti-static technology. It eliminates the risk of safety issue, facility hazards and truck damage.

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September 2019

THE INDUSTRY’S FIRST NON-MARKING ANTI-STATIC TIRE NEW

SOLIDEAL PON 775 NMAS BY CAMSO

Find out more at camso.co/PON775NMAS September 2019

Warehouse Solutions Insert n 15

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