M AT E R IA L S HANDLING
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c o n te n ts 3 5 6 3 6 14 8 16 4 10
INTRODUCTION:
FOREWORD:
James Pozzi sets the scene for ’s Materials Handling 2014 supplement
An introduction from James Clark, secretary general of the British Industrial Trucks Association.
HANDLING THE FUTURE:
Insight into industry trends from the British Industrial Trucks Association.
HANDLING THE FACTS:
UK material handling statistics.
DOOSAN:
Doosan defines materials handling best practice with two manufacturing case studies.
Editorial
This report was compiled for BARA by: Jane Gray, Editor j.gray@sayonemedia.com
Design
Martin Mitchell, Art Editor martin@opticjuice.co.uk
Sales
Matt Chilton, Project Director m.chilton@sayonemedia.com
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MATERIALS HANDLING
E DI T O R IA L
I N T R O D U C T I ON T h e c am paig n t o e s t abl i s h bet t er s t an d ar d s in t h e heav y l ift in g i n d u s t r y r e f lect s th e in c r e as e in s o ph i s t i c at ed w o r kin g s t an d ard s i n U K an d beyo n d .
S
olving the practical problems around the movement, storage, control and protection of materials, goods and products has always been a crucial part of the manufacturing process. But it’s fair to say the subject of material handling has often gone under many people’s radars. While trucks removing goods and materials are something of an industry unsung hero, this description can also apply to the recognition of material handling as a force in the UK economy as a whole. As the recession hit in 2008, the sector endured; capitalising on the increase in warehouses across the UK due to the online retail boom. In 2012, the UK material handling industry saw growth of 2.6%, it is predicted to grow a further 1% before the year is out. As consumer demands change, the need for effective materials handling remains paramount to a company’s efficiency.
Health and safety has also greatly affected the industry, and necessitated level of training and skills in order to fall within required standards. Whether you are a big player like Toyota Material Handling and Jungheinrich, or a smaller, regional firm, many have found the need to seek advice and support from industry trade bodies to make sure they are meeting these change challenges appropriately. These bodies inform and raise the standards of the industry and the British Industrial Truck Association (BITA) and the Lifting Equipment Engineers Association have both led the way in engaging industry in the increased emphasis on health and safety in the workplace in order to boost compliance and competitiveness. In this supplement, we give recognition to the materials handling industry as one of Britain’s most robust sectors and a key enable of recovery in the wider manufacturing base.
James Pozzi Associate Editor, The Manufacturer magazine
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The UK’s Largest Intralogistics Event IMHX IS THE MUST-ATTEND EVENT FOR ANY COMPANY OR INDIVIDUAL INVOLVED IN THE HANDLING, MOVEMENT OR TRANSPORTATION OF GOODS THROUGHOUT THE SUPPLY CHAIN. To book your stand call: Rob Fisher on 020 7017 6986, or email rob.fisher@informa.com
Follow us:
THE ESSENTIAL
intralogistics event
13 – 16 SEPTEMBER 2016 NEC BIRMINGHAM
www.imhx.biz
MATERIALS HANDLING
B R I T I S H
I N D U S T R IA L
T R U C K S
A S S O C IA T I O N
F o rew o rd M
Manufacturing and forklifts are both essential drivers of the UK economy. The UK’s continued excellence in manufacturing is a mainstay of our economy, but forklifts are a vital enabler of manufacturing and indeed all businesses that rely on materials handling. Without forklifts, goods simply would not be delivered. The British Industrial Truck Association (BITA) is a trade association representing a membership of forklift truck manufacturers, suppliers and service providers. Many of our members, of course, are manufacturers themselves, making and distributing over 90% of all new forklifts procured each year in the UK. The forklift industry employs some 7,000 people directly, and enjoys a combined annual turnover of £1.3bn. It also shares many strategic objectives with manufacturing, such as the need to attract young people into apprenticeships. It’s easy to assume that forklifts are all the same. In fact, they come
in a wide variety of designs with specific, as well as general, roles to play in a work environment. What they share is the ability to improve efficiency. The right forklift, or fleet of forklifts, can boost productivity by moving products or raw materials in a highly-efficient manner – thereby contributing to a manufacturer’s bottom line. Equally important in a manufacturing environment is safety. Safety may not be an obvious profit centre but in truth, it’s the key asset that every business should seek to maximise. At BITA, we prioritise two key factors in safety. The first of these is ‘managing in’: adopting best practice based upon industry-wide consensus, instilled via training and reinforced by consistent day-today application. The second factor is ‘designing in’: ensuring that all the tools for the job, from clothing and buildings to lift trucks and warehouse shelves, are appropriate, safe and fit for purpose. Why not contact a BITA member to see how investing in forklifts could help your business?
James Clark, SecretaryGeneral of BITA
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British Industrial Trucks Association
HANDLING THE
future T hr o u g h o u t t he g lo b al eco n o mic c risis s p a n n in g t h e las t f ive years , t h e UK’s m a t er i al h an d lin g s ect o r rem ain ed strong. Ja m e s P o zzi t a lks t o t h e B rit is h I ndustrial Tr uc k A s s o c i at io n ab o u t t h e s ect or’s g r o w t h an d h o w it en g ag es it s s ize able m e mbe r s h ip bas e.
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013 remains a positive time for the material handling sector. Currently in a state of yearon-year growth, albeit modest, the sector stands to benefit from the return to manufacturers investing in their companies. In 2011, the industry saw annual figures approaching 1.9% growth. In 2012, it was getting close to 2.6%, while this year it is estimated to be around 1% year-on-year. With such a steady consistency during the bad times, the prediction of better times brings with it high optimism. At the forefront of industry representation is the British Industrial Truck Association (BITA). With board members drawn not just from the big lift truck manufacturers such 6
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as Toyota Material Handling and Jungheinrich UK, but also from relevant component manufacturers such as Hoppecke Industrial Batteries, it is the UK’s biggest material handling trade body. Its membership covers around 75% of the industry and BITA operations are directed by the aforementioned management board, supported by three full-time staff members and a technical consultant working out of its head office in the Berkshire town of Sunninghill near Ascot. So having experienced steady growth underpinned by resilience in the face of market turbulence, what is this specialist industry’s secret?
The answer lies in the rise of digital retail, with its offshoots offering opportunities for manufacturers.
Robust in turbulent times
James Clark, BITA secretary-general since 1999, feels the robustness of the industry lies in the recessiondefying boom of warehouses during 2007-2012. With internet retailers such as Amazon and online supermarkets emerging, the increase in warehouses for logistics operations was sizeable. “Where everyone can see growth is in all these large warehouses and distribution centres springing up around the country as our shopping habits change and more people buy online. Forklifts have proved to have an instrumental role in fulfilling ecommerce orders and you will literally have hundreds of trucks inside those places ensuring orders are gathered and despatched efficiently,” he says. But this isn’t to say it was all plain sailing during the downturn years. Like most industries, material handling had to negotiate choppy waters. But what set it apart from other sectors was the fact it was able to bounce back quickly. “We certainly had a dip like everyone else, but luckily this was short lived,” says Clark. “While we are not quite back to our pre-recession figures, there’s a lot of sector resilience considering we’ve experienced the worst global recession for over fifty years.”
Meeting the challenges
Changing industry standards, such as the introduction of new regulations, has also had a noteworthy influence on BITA’s recent activities. Clark is quick to endorse these changes – predominantly in Health & Safety – as positive ones. “This is because the changes have largely been practical and geared towards operational safety; common sense decisions,” he says. As you would expect of a trade association, BITA has a key role in keeping its members abreast of steps necessary to comply with EU directives on safety, noise,
MATERIALS HANDLING
electromagnetic compatibility (EMC) and pollution and emissions. Likewise, Clark says, forklift buyers within the manufacturing sector need to be aware of the dangers of buying non-compliant trucks. A CE marking is absolutely essential, he says, adding: “If a truck isn’t certified then companies should be wary as it may have safety defects which aren’t allowed in the EU at all, just like an MOT. Buying from a BITA member is a guarantee of compliance.” And then there is the ever demanding skills issue. The industry currently needs 200 apprentices a year to replace the senior staff as they retire. To help address this industry need BITA set up the BITA Academy to help train apprentices in essential maintenance and repair techniques as well as equip them with the skills needed to pursue a career all the way to management level.
evolves – “exciting developments” are on the horizon. This is reflected in BITA’s other activities. In March it held its flagship IMHX exhibition in Birmingham, The event attracted over 19,500 visitors and a record 412 exhibitors and plans are already afoot for the next exhibition in September 2016. Clark believes enthusiasm for the event is an illustration of the industry’s strength – and of IMHX’s powerful role as a catalyst for generating new business. Given that BITA has already sold 50% of its tickets over two and a half years in advance,
BITA’s membership covers around
75%
of the industry The material handling industry experienced growth of in 2012 This year’s IMHX exhibition saw
2.6%
19,500 412
IMXH is certainly in rude health, boosting BITA’s coffers and therefore its ability to serve its members. Just as importantly however, it is an essential platform for engagement, keeping BITA in touch with member sentiment and experience. “As an event co-owner it really gives a chance to show what we can do, yet also get first-hand accounts of what is happening in the sector,” concludes Clark.
visitors and a record exhibitors
For forklift manufacturers and service firms, it provides a steady supply of fresh new engineers to keep the industry running smoothly in the years ahead. The demands are great, as the modern lift-truck market encompasses both internal combustion and electric power sources, which require different skills from maintenance engineers. While the academy successfully produces apprentices annually, BITA is looking at the way it delivers its programmes to ensure it best meets industry needs as the apprenticeship landscape
“ Like most industries, material handling and the industries it served also sailed through c hoppy waters. But what set it apart from other sec tors was the fac t it was able to bounce bac k quic kly.”
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MATERIALS HANDLING
facts and figures
HANDLING THE
facts
The global market for new industrial trucks is projected to reach just under one million units in 2013 and grow to over 1.23 million units by 2017
1.23million
Fast facts on the UK material handling industry. Despite the sluggish economic conditions of the last five years, the material handling sector remained particularly robust during that period. Having seen sales by nearly 20% in 2011 from 2009’s market low, sales throughout 2012 continued to grow. Last year saw a rise of 2.6% for the industry. By the end of 2013, it is expected to have grown a further 1%. With the UK said to be outstripping the likes of the US and Germany in terms of productivity, its place as a leader in a global industry estimated to be worth £60bn by 2015 is a notable achievement. James Clark, secretary general of the British Industrial Truck Association, said the rise in figures, a result of increased investment habits, were aided by the sector’s robustness. “While we are not quite back to our prerecession figures, there’s a lot of sector resilience considering we’ve experienced the worst global recession for over 50 years,” he said.
£60bn £60bn
£60bn
£60bn
£60bn
£60bn
£60bn
The material handlings industry is forecast to be worth £60bn globally by 2015
Source: Modern Materials Handling
In 2012, the UK material handling industry saw
2.6%
growth, while this year it is estimated to grow by a further
1%
World forklift sales by region in 2012
Asia Europe America Oceana Africa 8
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362,911 310,503 229,746 21,060 20,185
Doosan
Doosan delivery helps boost Bearmach Starting life as a small family company, Bearmach has grown to become one of the UK’s largest independent suppliers of Land Rover parts and accessories.
B
earmach is now an authorised European distributor for Land Rover and Jaguar, supplying to well over 120 countries worldwide. With goods constantly being shipped in and out of its two operational sites, covering more than 50,000 square feet in Caerphilly, Wales, the company was keen to streamline its materials handling movements and enhance safety. To help achieve this, Bearmach sought Doosan’s ‘simple powerful performance’ and turned to authorised dealer Gwent Mechanical Handling. The result was a fleet of five new Doosan trucks – four compact three-wheeled electric counterbalance trucks (B15T & B20T), alongside a LEDH 18 powered pallet truck. The trucks were supplied with customised extending forks, increasing the safety and stability with which Bearmach is
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able to move around the parts and accessories – including high-end products like body shells, panels, and even complete Land Rover and Range Rover chassis – that are the backbone of the business. The operator compartments on the Doosan forklift s have been designed with driver comfort in mind. Optimised pedal positions, ergonomic hydraulic levers and a fully-adjustable steering wheel all help to reduce operator fatigue and maximise productivity. And, with safety paramount in Bearmach’s busy work environment, the fact that these ultra-manoeuvrable trucks have oil-cooled disc brakes and the latest operator sensing systems fitted as standard provides additional peace of mind. Richard Green, Supply Chain and Operations Manager at Bearmach said “They are powerful, reliable and costeffective and an added bonus is that we now have forklifts with weatherproof cabs, which is always a great help with the weather we usually get in Wales!” Since taking delivery of the new Doosan trucks, Bearmach has noticed a clear increase in productivity and with greater order efficiency there have been cost savings too. A focus on reliability, safety and operator comfort has allowed Doosan to become a leading provider of forklifts in the UK. With high-specification features and proven technology, Doosan also boasts the lowest total costs of ownership.
MATERIALS HANDLING
water treatment plants, bottling and storage areas to navigate. The tight spaces need careful negotiation. With lots of forklift users on site, 35 operators are trained to operate the forklift fleet, the simplicity of Doosan’s truck made it more popular than other complicated machines that took part in demonstrations.
Sweet success for Aspall Cyder Premium Cyder specialist Aspall is amongst the top ten oldest family businesses in the UK. For the past eight years, Doosan’s Pro-5 forklifts have helped to bring a little extra fizz to the 285 year old Suffolk site.
F
ounded in 1728 by Clement Chevallier, Aspall Suffolk Cyder is owned and managed by the eighth generation of the Chevallier family.
Taking its inspiration from the apple tree for three centuries, the company produces a range of award-winning cyders, vinegars and apple juice; and is now the UK’s oldest independently-owned cyder producer and last remaining English family owned vinegar brewer.
“When you have a business steeped in tradition and heritage,” adds Henry, “you tend to place a lot of emphasis on establishing good working relationships over the long term. We are obviously growing as a business, and that means we need a supplier that can support us over the long term, with reliable, cost-effective equipment.” Some new modifications have been included on this latest delivery of two and three tonnes capacity machines. Most kegs have been moved off site, but a small run of kegs continue for export and a wayward keg can prove dangerous. To keep them in their place the load back rests were modified, whilst an additional roof guard adds an extra level of protection to the operators. Building rugged, reliable, yet simple trucks has allowed Doosan to become a leading forklift provider. The range of electric, LPG and diesel Pro-5 models is Doosan’s most successful ever, with a host of features including trademark oil cooled disk brakes, integral sideshift as standard, plus award winning safety features and class-leading ergonomics. It all means companies like Aspall can rely on the best possible equipment for their expanding businesses. And with recipes handed down through generations, methods developed through centuries of careful development and the latest equipment at their finger tips, the future sweet success of Aspall is no doubt guaranteed.
A Doosan forklift user for over eight years, it lays claim to an impressive heritage in cyder making and place a great deal of emphasis on establishing long-term relationships with suppliers. Today the super premium cyder brand is a recognised leader in its field and is exported across the globe. The brand has its own legion of fans, and counts rapper Professor Green, comedian Ade Edmondson, and thousands of drinkers in Thailand, the U.S., Germany , France, Ireland, Russia, Japan, Brazil, Australia and New Zealand amongst them. “We don’t compromise on quality,” says Henry Chevallier Guild, who heads up the business together with elder brother Barry. “if it doesn’t taste premium quality, we don’t make it.” Having time honoured processes and deep roots does, however, create its own issues. One challenge presented by the site is space. Every inch is utilised as best it can be, and new developments, like the recent addition of new fermentation tanks, has to be mindful of the adjacent family home. The elegant, moated, Aspall Hall has been owned by the Chevaliers since 1702. Beside the pressing room there’s also the
Doosan Industrial Vehicle U.K. Ltd. 12 Kilvey Road Brackmills Industrial Estate, Northampton, NN4 7BQ Tel: 01604 825600 Fax: 01604 825650 www.doosanforklifts.co.uk
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