JUNE.2013
busridemaintenance.com
the exclusive maintenance resource for the transit and motorcoach industry
Stertil-Koni improves grows and
p5
Certification ensures safety p6 Six principles for safe lifting p8 Prevent slips, trips and falls p12
LETTER FROM THE INDUSTRY
Christopher W. Ferrone, President Americoach Systems, Inc. Glenview, IL
‘Worse for wear’ has a number
T
he difference in degrees of mechanical wear on the equipment between city use and highway driving can be significant. In 30 years of tracking maintenance and keeping records of engine, transmission, brake, HVAC and accessory life cycles in city driving and comparing them to the same components in use on the highway, I have been able to formulate a ratio that relates the wear rate of one city mile compared to one highway mile. I arrived at the numerical ratio of 3.17:1 — 3.17 miles of comparable highway wear for one mile city of city driving. An operator who has done only highway work in the past would have to accelerate his maintenance planning by a factor of 3.17 to maintain the vehicles at the customary level in the city. For example, I expect a 6V92 engine driven in the city to last approximately 185,000 miles before failure. On the highway, I can expect an engine to last about 585,000 miles. Of course, motors such as this are now few and far between, but do lend themselves as a great data point for this study. Other motors will wear at approximately this same rate. For brakes in city driving, I expect approximately 40,000 miles and about 120,000 miles on the highway. Operators can use this information to compare wear rates within their fleets and confirm any disparities between city and highway driving. This ratio would not be necessary if the operator ran either city or highway miles exclusively. Since most companies do not have this luxury, this data is very helpful. In any event, empirical data is imperative to operators who want a better understanding of wear, performance and the capability to predict life cycles of components and systems.
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Vol. 03 • No. 05 Publisher / Editor in Chief Steve Kane steve@busride.com Associate Publisher Sali T. Williams swilliams@busride.com Editor David Hubbard david@busride.com Managing Editor Richard Tackett rtackett@busride.com Senior Account Executive Andy Pieri apieri@busride.com Account Executive Maria Galioto mgalioto@busride.com Production Director Valerie Valtierra valerie@busride.com Art Director Stephen Gamble sgamble@theproducersinc.com Accountant Fred Valdez fvaldez@powertrademedia.com
BUS industry SAFETY council
A publication of:
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JUNE 2013 CONTENTS
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The company gets a lift Stertil-Koni commits to improving safety and efficiency in products and technology
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Certification trumps cost MAHA USA stresses safety training and routine inspections for all ALI certified lifts By Radu Pop
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Six principles for safe lifting Using vehicle lifts improperly is extremely dangerous for garage techs By Steve Perlstein
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ADA mandates say keep it operative ADA maintenance requirements require attention to all accessibility components By Elaine R. McCloud
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DEPARTMENTS LETTER FROM THE INDUSTRY
Fall protection is law The safest fall protection systems surpass normal standards
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By David Hubbard
Nine tips for high-density storage Reduce time, labor and resources costs By Tim Vaughan
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lift The company gets a Stertil-Koni commits to improving safety and efficiency in products and technology.
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tertil-Koni, Stevensenville, MD, a manufacturer of heavy-duty vehicle lifts, recently announced a major capital investment at its U.S. manufacturing facility, Stertil ALM, Streator, IL. The enhancements represent completion of the first phase of a substantial, ongoing commitment to plant modernization and efficiency. For example, the company installed a state-of-the-art computerized cutting machine that utilizes a combination of plasma and oxy-fuel torches for extremely fast, highprecision manufacturing. Allan Pavlick, vice president, Stertil ALM, says as a result, the company now has the ability to cut virtually all components required in-house. Stertil-ALM also added two new, high capacity overhead cranes to its facility. “These new innovations permit us to save time and money, while simultaneously enabling Stertil ALM to expand its commitment to hiring local workers,” says Dr. Jean DellAmore, president of Stertil-Koni USA, in a statement. “From a broader perspective, our investment in the latest technology also enables Stertil-Koni to bring product to market even more quickly and expand the company’s leadership in the design and production of top-rated heavy duty vehicle lifts.” The Streator facility focuses on the production of a broad range of Stertil-Koni heavy duty vehicle lifts. The product line ranges from mobile column lifts and platform lifts to the Ecolift — the industry’s first US patented, ultra-shallow, fill-rise, in-ground scissor lifting system. The breadth of products meets all ranges of lifting needs and includes mobile lifts, two-post, four-post, in-ground lifts, parallelogram lifts, half-scissors lifts and the axle-engaging, in-ground, scissor-style heavy duty hydraulic lift configuration. The company says its lifts are ideally suited to a full range of heavy duty vehicles such as buses and motorcoaches, as well as articulated buses, fire and rescue vehicles and
multiple axle trucks. Stertil-Koni says it differentiates its technology on a number of additional performance fronts. 1. The hydraulic cylinder is designed and installed in the mobile lifting column to protect the seals. Only the piston rod is exposed during lifting. 2. In the case of power failure a Stertil-Koni mobile lifting column has provisions to allow manual lowering. 3. The unique synchronization system starts at a height difference of just 9/16 of an inch, ensuring safe and smooth lifting and lowering cycles regardless of weight distribution. 4. As an added safety feature, the Stertil-Koni mobile lifting column is designed with ample clearance between the column and the vehicle. 5. The standard length of the lifting fork is 14 inches, thereby accommodating proper and safe lifting of vehicles with super single tires. 6. Stertil-Koni hydraulic mobile lifts are equipped with self-lubricating synthetic wheels and a hydraulic pallet jack mechanism that incorporates a patented gas spring, making the column particularly easy to relocate.
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Certification trumps cost MAHA USA stresses safety training and routine inspections for all ALI certified lifts. By Radu Pop MAHA USA, Pinckard, AL, unites German engineering with quality American craftsmanship to produce the only wireless mobile column lift powered by ball-screw technology. The ball-screw is splash-proof and dirt repellent and promises minimal mechanical wear. This technology is trusted in high-precision market segments and has proven to be the most reliable for high mechanical efficiency. Safety is the primary factor to consider in selecting a vehicle lift, which means investing in a quality lift that is certified. A nationally recognized independent testing laboratory, such as the Automotive Lift Institute (ALI), guarantees manufactures have met specific safety standards and that the lift is worthy of its golden certification label.
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Proper maintenance and routine inspections are the best ways to ensure safety awareness remains the number one priority.
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Not all lift manufactures are capable of meeting the safety standards for certification. More than a few lifts are sold “uncertified,” often at a lower cost, compromising safety for the technicians. Technicians should ask, “Will I trust myself to stand under a vehicle when the supporting lifting device has not undergone rigorous testing?” The answer has to be no. Once the company has selected the appropriate certified lift for the shop, proper use and safety training is next. No matter how advanced the lift is, its use defines its operation. Like most manufacturers, MAHA USA offers a strong and efficient support network of factory trained technicians and a large distributor base to provide a comprehensive selection of training sessions with the ability to competently convey technical knowledge to users of all levels. Do not disregard the operator’s manual. Many operators tend to start using the equipment without making themselves fully aware of proper safety procedures. As operator error is the cause of most accidents, only proper training can ensure a safer, more efficient operation and prepare the user for emergencies. Proper maintenance and routine lift inspections are the best ways to ensure safety awareness remains the number one priority. Most manuals have a periodical maintenance procedure. The company can also contact the manufacturer or representatives in the field for information and correct service instructions. A greased lift is a happy lift. Keeping the equipment clean and lubricated ensures a long service life. As time
goes on, check for signs of wear and mechanical failure associated with aging. Lifts get old too, so routinely inspect any items like cables and rollers and replace when necessary. ALI recently introduced a program for Certified Lift Inspectors, which makes it easier and more convenient to connect with a certified technician to take care of and inspect ALI-certified lifts.
Like most manufacturers, MAHA USA offers a support network of factory trained technicians to provide a comprehensive selection of training sessions.
Radu Pop serves as a market research analyst and heavy-duty equipment specialist for MAHA USA, Pinckard, AL.
Help your team prepare like these technicians: “Excellent study tools, provided proper ASE terminology which is needed to pass.” - Peter “Materials help build confidence and understanding of what you need to know to pass these exams.” - Frank “I like the online practice tests. I did them over and over until the material was etched in my head; it was easy passing the test after that.” - Marco
Print manuals covering the Transit Bus ASE exams are also available. Call 800-998-7498 x2595 to receive your trial or to inquire about Delmar ASE Test Preparation products! www.TechnicianTestPrep.com/TransitBus/Intro.aspx *Trial offer available exclusively for managers responsible for training technicians. Offer expires 7/1/13.
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principles for safe lifting
Using vehicle lifts improperly is extremely dangerous for garage techs By Steve Perlstein
You’d never drive a vehicle that hadn’t had the brakes inspected in years. You would never use a jack without also using a jack-stand. These basic and common sense principles apply to vehicle lifts in your maintenance facility and daily inspections are part of your job. The vehicle lifts that are supporting the buses being repaired in your garage can represent one of the most productive tools in your shop, or one of the most dangerous pieces of equipment for your techs if not used and maintained properly. Whether you’re using two-post lifts for cars and light trucks, parallelograms, mobile column lifts, drive-on lifts or in-ground lifts for servicing vehicles, you should follow these basic safety rules. 1. Buy certified lifts There’s only one nationally recognized safety standard for vehicle lifts: ANSI-ALI/ALCTV, administered by the Automotive Lift Institute (ALI/ETL). ETL testing labs verify that a manufacturer’s lifts meet the national safety standards for vehicle lifts. The Automotive Lift Institute working though ETL testing procedures involves rigorous third-party testing verifying lift manufacturers comply with current ANSI requirements for lifts as defined by the International Building Code, which mandates that lifts be third party tested to meet these safety requirements. To verify equipment status, look for the gold ALI/ETL certification tag next to the lift’s controls. 2. Buy certified lift options A commonly overlooked mistake is using an uncertified option or accessory on a certified lift. Doing so will void the lift’s certification. It’s simple: If the optional accessory isn’t certified then the lift isn’t certified. ALI/ETL standards (& ANSI standards & building code standards), require all accessories, such as drive-on lifts, rolling jacks and truck adaptors, to be certified. Although certification is good for the life of the lift, older models may not meet the most current standards. Complying with American National Standards Institute (ANSI), Occupational Safety and Health Administration (OSHA) and Public Employees Occupational Safety and 8
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Like any product, lifts vary in style, type, capability, longevity and warranty.
Health (PEOSH) requirements is the key to keeping vehicle lifts at the highest possible safety level, sending your technicians home safely after each shift, and avoiding write-ups or hefty noncompliance fines. 3. No locks are liability You’ve heard the phrase, “Never use a jack without a jack-stand.” The same is true for vehicle lifts. Always raise the vehicle and then lower it onto the lift’s mechanical locks as required by ANSI. Refer to ALI safety manual Lifting it Right or the manufacturer’s operating instructions for detailed information. When you’re walking through the shop, make sure techs are using the proper procedure. An easy way to visually verify the locks are being used is to include a weight gauge (a pressure gauge calibrated to the lift’s lifting capacity) on your lift. A weight gauge can also be a great diagnostic tool. If using an old in-ground lift that doesn’t have locks, it’s time for a new lift. While some in-ground lifts can be retrofitted with an aftermarket lock, it’s not the most cost-effective option, and your lift will still not be ALI/ ETL certified to be compliant with ANSI rules and building code laws. 4. It’s easy to overload Manufacturers of the most common two-post sideby-side lifts mandate that none of the four swing arms be overloaded. busridemaintenance.com
For example: Some may think that a 15,000 pound rated lift that’s loaded with a 14,200 pound ambulance isn’t near capacity. They’re wrong! This ambulance has a front axle weight of 4,000 pounds and the back axle weighs 9,200 pounds. The per-arm capacity of 15,000 pound-rated lifts is 3,750 pounds. If the heavier rear end of a vehicle weighs 9,200 pounds, each swing arm needs a minimum arm capacity of 4,600 pounds for safe lifting. Multiply this example by four swing arms and the minimum capacity of your lift for this vehicle should be 18,400 pounds. It’s easy to see why two-post side-by -side lifts are often overloaded, even though the total lift capacity hasn’t been exceeded.
Make sure techs are using proper procedure with heavyduty vehicle lifts. Steve Perlstein serves as sales manager for Mohawk Lifts, Amsterdam, NY.
5. Inspect equipment annually ANSI/Automotive Lift Institute ALCTV Standard for Automotive Lifts – “Safety Requirements for Construction, Testing, and Validation” requires technicians to perform a daily operational safety check. The code also requires an annual inspection by a qualified individual. Failing to do so exposes your shop to liabilities that could be associated with an injury if an accident were to happen. 6. Training and testing Like any product, lifts vary in style, type, capability, longevity and warranty. ANSI requires technicians to be trained annually in proper lift use. Contact the Automotive Lift Institute, your lift supplier, or a local lift inspection company for a copy of the 20-minute Lifting it Right video hosted by legendary NASCAR driver Richard “The King” Petty and his son, Kyle. Require your technicians to watch the video and pass a written test on lift operation and safety.
CHANGE THE WAY YOU APPROACH LIFTING
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We give our customers the power to maximize daily service operations with one of the largest selections of workshop equipment in North America. Manufacturers of the most common two-post sideby-side lifts mandate that none of the four swing arms be overloaded.
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ADA
mandates
say
ADA maintenance requirements require attention to all accessibility components
Drivers should fully cycle lifts and ramps before beginning their shift.
By Elaine R. McCloud The Americans with Disabilities Act of 1990 (ADA) requires public transportation agencies and private operators to maintain all equipment related to accessibility and mobility for the disabled in a state of good repair. The process entails ADA training, routine inspections, maintenance, monitoring and investigating complaints.
Keep equipment in operative condition The components ADA mandates maintenance and upkeep on are wheelchair lifts, ramps, kneeling mechanisms, automatic stop announcement annunciators, wheelchair securements and tie-down devices, fare payment equipment and public address systems, as well as technology to facilitate communication with passengers with impaired vision or hearing. ADA mandates prompt repairs Any breakdown or maintenance issue associated with accessibility features requires immediate attention and prompt repair. When an accessibility feature is out of order, the operator must take reasonable steps to accommodate individuals with disabilities who would otherwise use the feature. Occasional isolated temporary interruptions in service or access due to maintenance and repairs do not constitute illegal discrimination. However, a continuing pattern or an overly long interruption in service could be discriminatory. It is a failure by operators to make diligent efforts to keep accessibility equipment in working order. Perform regular and frequent maintenance Transit agencies must be able to provide a verifiable record of frequent inspections and maintenance of bus lifts and ramps tested with a full load. Tested empty, lifts might appear in working order but may incur problems during testing with weight comparable to that of a passenger using a wheelchair. 10
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Drivers should fully cycle lifts and ramps before beginning their shift, and be certain all necessary securement and restraint components are functioning. Such pre-trip inspections by drivers also ensure they know how to work each piece of equipment before leaving the garage. Put inoperative vehicles out of service ADA states a transit agency must take a vehicle out of service the moment a lift or ramp becomes inoperative, and returned to service only after all repairs or replacements are complete. Under no circumstance can an operator put a bus with a broken lift or ramp into service on any route. There are exceptions for communities with a population of 50,000 or fewer. If no other vehicle is available, and if taking the vehicle out of service would reduce the transportation service available to the general public, the transit agency may keep the vehicle in service for no more than five days; three days in areas with a population larger than 50,000. Post-trip inspect problem equipment When failures of accessibility equipment occur on a bus run or shift, conduct an immediate maintenance check when the vehicle returns to the yard. Records must also include instances in which no apparent problems were found for the reported failures. If this becomes a pattern for a particular bus, conduct more extensive diagnostics on the components in question. Policies and training ensure compliance ADA makes compliance imperative. Operating without detailed, written policies and procedures that address busridemaintenance.com
each ADA maintenance requirement invites serious inconsistencies in compliancy. These policies must be the focus of all training. Preventive maintenance rules Using the recommended OEM preventive maintenance information, transit agencies should develop detailed inspection and maintenance checklists for fall accessibilityrelated items. Mechanics are to completely attach these checklists to the primary inspection form to verify all recommended inspections and preventive maintenance. Adhere to a schedule to clean and lubricate lift and ramp mechanisms frequently to protect the lift and improve its reliability. Maintain a parts inventory The manufacturers of accessibility equipment can supply a list of parts to purchase and keep in stock, as well as the quantity of each part. A review of maintenance and repair records can serve as the base to determine the needed parts.
Investigate all complaints Thorough investigation of all complaints from disabled and impaired customers is critical to ADA compliance. The upshot is that transit officials can then use information obtained from investigations to address any performance issues and improve service. Progressive discipline for the more serious infractions is important to a consistent ADA program. Transit and paratransit vehicle operators and maintenance employees need to know their performance and work is monitored, and to be mindful of the consequences to the agency and to themselves for violating established policies.
Elaine R. McCloud, a 30-year paratransit and mass transit industry veteran who is president and chief executive officer of McCloud Transportation & Associates, LLC, helps public and private sector entities comply with the vehicle maintenance requirements of the ADA.
Be certain that all necessary securement and restraint components are functioning during pre-trip inspections.
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Fall Protection is law The safest fall protection systems surpass normal standards By David Hubbard Fall protection systems resolve the challenges and danger most maintenance facilities encounter for technicians who must perform repairs and replacements atop the vehicle. The tasks workers engage in at this height typically put them at high risk for slips, trips and falls. While bus and coach companies must unquestionably be concerned for worker safety in these situations and take extra precautions, fall protection specialists tell us that regulated fall protection with advanced equipment has been slow to evolve. There was a time when technicians on the roof did their work with little more than ropes tied around the waist. Fall protection is law in the modern age. The OSHA Fall Protection Code stipulates that fall protection equipment be provided for workers engage in elevated activity at a minimum of four feet above the floor. OSHA also requires some sort of self-rescue capability or a way to promptly rescue a worker who has fallen. Rigid Lifelines, Morgantown, PA, a division of SPANCO, takes the issue of compliance a step further. “OSHA allows a number of fall protection options that are legal within the law,” says Rigid Lifelines Marketing Manager Michael Evanko. “However, OSHA law is a bit vague and not truly up to date with recent developments 12
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Rigid Lifelines says facilities will support the installation of its fall protection systems without any welding.
in equipment and technology. A system may be compliant under the law, but not necessarily protecting workers as best it should.” The company says maintenance directors responsible for implementing a fall protection program within their company will find the ANSI Minimum Requirements for a Comprehensive Managed Fall Protection Program more beneficial. “The ANSI standard clearly defines all the duties and responsibilities that OSHA will require from an organization using fall protection,” says Evanko. “Additionally, it covers issues that OSHA does not address, such as hazard analysis, rescue plans and anchorage requirements for fall restraint systems.” Fall Protection Systems (FPS), Florissant, MO, and Rigid Lifelines both provide rigid rail systems for bus and coach maintenance applications that attach to the ceiling of an existing facility. Though each have their proprietary features, the systems basically feature a path of rigid track running the length of the maintenance area. Multiple tracks may be installed to support more workers. Each worker, wearing a harness and retractable lanyard to a rolling trolley, moves back and forth. This allows them to move freely across the busridemaintenance.com
With a maximum fall distance of two feet, this system minimizes injury by allowing the worker to easily step back to the roof of the vehicle.
roof of the bus, as opposed workers harnessed to a cable stretched between two points. “The difference in the length of a free fall between these two types of systems is significant,” says Evanko. “The chance for serious injury increases with the length of free fall. Working from a rigid rail and retractable lanyard, if a worker were to fall, the system immediately engages fall arrest quicker.” With a maximum fall distance of two feet, this type of system clearly minimizes injury by allowing the worker to easily step back to the roof of the vehicle, and not be left hanging and dangling. No welding with Rigid Lifelines Rigid Lifelines says, assuming the building has been approved, and most large transit maintenance facilities have, facilities will support the installation of its fall protection systems without any welding. “This can be a big deal, because many bus maintenance facilities have rules in place that prohibit welding indoors because of the many flammable liquids and materials in use under roof,” says Evanko. “This is never an issue with our systems. Where rope or cable systems often require welding reinforcements to the structure to support the weight forces applied during a fall, our installation only uses bolts to secure all the components.” He says if a worker was to fall and not be deflected toward the ground before the system activates, the retractable lanyard would engage immediately. With a rope or cable system that is typically a little looser, a person would actually fall a longer distance before fall rescue.
Fall Protection Systems Mass Transit Repair & Maintenance Safety
FPS offers turnkey solutions FPS, a 20-yearold company, has installed fall protection solutions for maintenance bays servicing a variety of transportation vehicles. The company says it is the only fall protection provider to provide a turnkey system. “Every necessary component and service is included in our turnkey solutions,” says FPS Senior Sales Manager Matthew Proctor. “Our process begins with an onsite visit to the facility where we conduct a site analysis and diagnose the client’s fall protection needs, such as number of vehicles and the size of the maintenance staff. Our engineers then work in-house using videos, photos and drawings to generate a 3D model of the proposed system.” FPS says its custom trolley-rail system fits into and around all features within the existing structure, leaving previously installed heaters, condensation pipes, ductwork and sprinkler systems in place. “FPS can install its system as one continuous piece of rail, offering an uninterrupted path to work along,” he says. Proctor says it also permits additional workers on the same system without putting them in harm’s way. If one worker falls, the enclosed rigid track will not bend or deflect.
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Reduce time, labor and resources costs. By Tim Vaughan High density storage is a sure way to reduce time, labor and resource costs in parts and service departments. It also improves profitability High density storage uses less space and makes keeping track of inventory easier by situating the highest volume parts for easier, faster access. Replacing existing storage shelves with high density storage units can reduce a parts department footprint by as much as 50 percent, while increasing the number of parts stored. Here are nine tips to implement and get the most out of a high density storage system.
2. Place a high density storage cabinet near the service counter. Stock the cabinet with the 100 to 200 fastest moving parts. Place it within easy reach of both the service department and walk-in customers for faster transactions. Keeping parts sold most frequently close to the counter also reduces foot traffic and time lost by going to the back room to find a part. Storing parts in high density drawers allows better inventory control. 3. Duplicate the fastest moving parts. Consider two walk-up positions at each checkout point.
1. Determine the fastest moving parts. Run a business management system report for the last 12 months that shows parts sales by unit volume. Make note of the most parts sold in that time and store as close to the parts counter as possible.
Use a drawer organization system.
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Place a high density storage cabinet near the service counter.
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Replacing existing storage shelves with high density storage units can reduce a parts department footprint by as much as 50 percent.
4. Organize high density 8. Store the correct size parts in storage cabinets by type. the correct sized drawers. The cabinet Organization of parts in the vendor takes a physical inventory of the cabinet is key and storage by part available space and prepares a layout type is the most efficient method. for placement. This shows the existing With labels affixed to the drawers storage and how much more can be and bins, anyone can easily locate gained with a new storage system. a part. This lowers retrieval time A rule of thumb says three to five significantly because 75 to 80 sections of shelving at about 9 to-15 Organize high density storage cabinets by type. percent of all the fast-moving linear feet can be condensed down to parts can be stored in this manner a single eye-level cabinet measuring at parts counter. For easier cross referencing, group about 28 inches by 28 inches. similar parts from multiple manufacturers. Shelving 18 inches deep and 84 inches tall uses no more than 50 percent of its capacity and sometimes 5. Select shelving for high density storage. A 5-inch as low as 30 percent. Some shelving or a bulk rack is cube or smaller is the optimum size to really take still necessary for parts that simply aren’t conducive to advantage of the power of high density storage. Do not storing in drawers, such as items that turn over too fast store larger, bulkier items in a cabinet. Shelving is the or are big and bulky. Setting up a counter with the most best option. popular parts stored in counter level cabinets will free up a 6. Use a drawer organization system. After determining significant amount of space. Parts sold infrequently can be what parts are a good fit, organize them into their exact stored away from high traffic areas. location using an alpha-numeric system, i.e. Cabinet A, 9. Use the extra space for something productive. A Drawer 1, Row A. successfully implemented high density storage solution 7. Use high density storage to conduct inventories. affords the advantage of additional space, which can Similar to balancing the cash drawer at the end of each be transformed into square footage for displays on the day, it is important to personally inventory fast moving selling floor or adding new product lines without requiring parts against the business management system at least additional storage space. three times per year. A “rolling inventory” based upon the number of times a part turns each year can reduce Tim Vaughan serves as vertical market manager for Automotive and the total time for an annual inventory and provide a more Outdoor Power Equipment Dealerships at Stanley Black & Decker’s accurate account of what you really have on hand. Lista and Stanley Vidmar businesses. busridemaintenance.com | BUSRIDE MAINTENANCE
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