Logistics & Materials Handling April 2014

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inside VOL44 ISS2 APRIL 2014

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Industry News Safety Training/Education Bulk Materials Handling Inventory Warehousing

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inside VOL44 ISS2 APRIL 2014 Industry News Safety Training/Education Bulk Materials Handling Inventory Warehousing

Truck industry calls for stability Heavy vehicle accidents prompt the need for change

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This issue April 2014

Logistics operations A new choice in fleet management

23

contents

Factory Materials Handling

06 Bulletin Board Government pours $125 million into freight productivity SCLAA commences energy saving workshops 08 Training and Education On the hunt for job seekers who can learn 10 Safety Heavy vehicle accidents prompt calls for change 12 3PL Outsourcing transport to overcome delivery problems 14 Bulk Materials Handling Manitowoc launches new automated counterweight system Driving in a new direction: GE launches new LHDs Self-erecting tower lift system saves time and money

18 Warehousing Mammut raises logistics performance with new distribution centre 20 Technology Australian wholesale distributors lag behind in E-commerce adoption

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21 Forklifts How to get the most out of your forklift fleet 22 Materials Handling Rio Tinto benefit from clever conveyor innovation 24 Inventory Customisable inventory solution Revolutionising online shopping for modern customers Updated mobile device helps retailers 29 Factory Materials Handling Conveyor investments cut energy costs

ASSOCIATE PUBLISHER: Martin Sinclair e martin.sinclair@cirrusmedia.com.au EDITORIAL CO-ORDINATOR: Vicky Validakis t 02 8484 0964 e vicky.validakis@cirrusmedia.com.au GRAPHIC DESIGNER: Dave Ashley t 02 8484 0710 e david.ashley@cirrusmedia.com.au KEY ACCOUNT MANAGER: Tim Richards t 02 8484 0829 e tim.richards@cirrusmedia.com.au QLD ADVERTISING MANAGER: Sharon Amos t 07 3261 8857 m 0417 072 625 f 07 3261 8347 e sharon.amos@cirrusmedia.com.au PO Box 3136, Bracken Ridge, Qld 4017 PRODUCTION CO-ORDINATOR: Mary Copland t 02 8484 0737 e mary.copland@cirrusmedia.com.au All rights reserved. No part of the publication may be reproduced or copied in any form or by any means without the written permission of the publisher.

ISSN 1832-5513 Copyright Cirrus Media. Published by Cirrus Media. (ABN 80 132 719 861) Tower 2, 475 Victoria Avenue, Chatswood, NSW 2067 Australia Locked Bag 4700 t 02 8484 0888 f 02 8484 0633. Printed five times a year, Logistics & Materials Handling is inserted in the February, April, July, September and November 2014 issues of Manufacturers’ Monthly, FEN, Australian Mining, Electronics News, Food, and PACE magazines with a distribution of 30,000.

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bulletinboard LOGISTICS AND MATERIALS HANDLING NEWS FROM AUSTRALIA AND AROUND THE WORLD

Government pours $125 million into freight productivity NATIONAL freight productivity will get a shot in the arm with the Federal government pledging $125 million to roll out several new projects.

Deputy Prime Minister and Minister for Infrastructure and Regional Development Warren Truss announced the money will be used to start the rollout of the Advanced Train Management System across the national rail network and for the next stage of the Port Botany Rail Line Upgrade.

“The Advanced Train Management System will lift innovation in the sector by replacing current high-cost, low-reliability trackside signalling with a state-of-the-art computer system that will underpin the national network’s future operations,” Truss said.

Truss advised the Australian Rail Track Corporation that $50 million is immediately available for the project.

While $75 million will go towards getting Stage 3 of the Port Botany Upgrade underway which will see the upgrade of the Port Botany Rail Line on segments that have sub-standard track conditions, such as poor ballast, replacing the last remaining timber sleepers with concrete, and replacing sections of worn or low weight rail with higher grade steel to increase load capacity.

“By including these projects into our $35.5 billion Infrastructure Investment Programme we recognise the importance of freight rail to our national prosperity and in unlocking our constrained economic productivity,” Truss said.

SCLAA commences energy saving workshops THE Supply Chain & Logistics Association of Australia is rolling out its Energy Efficiency workshops at aimed helping SMEs reduce their energy costs.

The free workshops will be held in 22 regional and rural areas over the next seven months and will provide companies who store and transport goods the information they need become more efficient.

“This will enable them to lower their cost of doing business and improve their competitive advantage,” the SCLAA said.

To assist SMEs most workshops will start at 7.30am and conclude by 10.30am and will also be available by webinar.

The SCLAA is also creating an online interactive tool which will provide businesses with a four-step guide on how to identify and implement energy saving opportunities.

Companies will also be able to download fact sheets, how to guides, case studies, examples of suppliers and details on grants available to SMEs.

6 | Logistics&MaterialsHandling April 2014

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training/education

On the hunt for job seekers who can learn Employers are increasingly looking for people with a demonstrated ability to learn, says recruiting experts Hays.

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ith unemployment sitting at ten-year highs of six per cent, most forecasters, say it will rise further.

According to recruiting experts Hays, jobseekers need to be aware of this year’s changing profile of the ideal candidate, with learning aptitude – or the ability to learn – the next battleground in the war for talent.

“Employers are starting to prioritise learning aptitude, in some cases over the technical skills and experience required in suitable candidates,” says Nick Deligiannis, managing director of Hays in Australia and New Zealand.

“It’s not just about finding the right skills and experience and matching cultural fit anymore. Today the ideal candidate also has a desire to learn and the aptitude to do so.

“The world is changing rapidly.

Globalisation, the shift towards a knowledge economy and the sheer pace of technological changes are among the factors radically shifting how organisations operate. This places a premium on an employee’s ability to learn and respond to their employer’s and the market’s changing demands.

“As such, employers want people on their team who can adapt and learn new skills.”

Advice for employers: With this in mind, Hays says a traditional and rigid skills-based approach to assessment and recruitment is no longer good enough.

“Aptitude testing has a long history in HR and recruitment, but while tests have a part to play in 8 | Logistics&MaterialsHandling April 2014

success it brought the business.

Examples could include learning a new technology or language, working in an overseas office or any situation where you have learnt and experienced something new.”

Logistics hotspots:

many recruitment processes, they are not enough to target an aptitude for learning,” Deligiannis said.

“Recruitment strategies targeting learning aptitude will need to evolve incrementally for most businesses, and will likely begin with existing roles. As businesses adapt to the changing demands of the market, it will become increasingly clear which parts of the organisation will need a greater affinity for acquiring new skills, and which will remain consistent.”

Deligiannis said recruiting for learning aptitude also demands a well-managed commitment to learning and development, with systematic opportunities for employees to develop themselves.

“This is a tough requirement in less hierarchical organisations, and presents a challenge around attrition, as employees hired for their desire to grow and adapt expect continual growth opportunities, and become increasingly desirable to competitors,” he said.

“HR will need to be on hand to guide the recruitment strategy.”

Advice for candidates: When it comes to candidates, educational and career background remain relevant but they are far from the only factors by which employers will measure your suitability for a role.

“At all stages of the recruitment process, from cover letter to interview, promote your ability and willingness to continuously develop and update your skills as the business and market demands,” Deligiannis said.

“Be prepared to be tested for learning aptitude, just as you might expect to be tested for attention to detail or other relevant aptitudes.

“Also expect to be asked specific questions about your ability to adapt and learn new skills. Prepare examples of how you have updated your skills in the past to the benefit of your previous employer.

Link your learning back to the

Store Persons – Due to the sheer volume of companies that engage store people, well presented, competent and enthusiastic individuals are always sought after.

Container Forklift Drivers – Container Forklift Drivers with CN licences are constantly in demand.

Fleet Controllers – There is a big gap between the lower level fleet controller role and the high end ones. This means that it is sometimes difficult to find the right candidate.

Cartage Coordinators – There is a major shortage of candidates as this is a role which is highly demanding and not very well paid compared to similar positions within the industry.

Imports/Exports operators with 2-3 years’ experience – The shortage of candidates in the industry 12 months ago drove everyone towards project based work. This created a significant shortage within the general forwarding space, particularly for those with 2-3 years’ experience.

Fleet Controllers across both metro and wharf operations – With an aging workforce the transport industry is struggling to attract new people into the industry as the mining industry is saturating the market. This is making it difficult to attract the talent needed into these so called entry-level positions. logisticsmagazine.com.au

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safety

Electronic rollover stability control with roll stability: It’s time

With the recent concerns over heavy vehicle crashes, two leading industry groups have come together to advocate change.

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he Australian Road Transport Suppliers Association (ARTSA) and the National Bulk Tanker Association (NBTA) are calling for the immediate adoption of Electronic Stability Control with a rollover stability feature on all new heavy vehicles.

They say the evidence for the adoption of this technology is compelling, with demonstrations showing that ESC adds a useful safety margin when heavy vehicles go around bends and can also help during avoidance manoeuvres.

Dr Peter Hart, chairman of the ARTSA, says there is no doubt that modern braking systems of the ESC type could save lives.

“Even experienced drivers occasionally misjudge the road conditions, “ Hart said.

“It is not a case of speeding; it is a case of misjudgement. Variable loading and slosh tankers is another problem factor.

“The intelligent control system can foresee a developing problem and intervene.”

According to Hart, the European Union has mandated electronic stability control (which includes a pending roll over response) on all 10 | Logistics&MaterialsHandling April 2014

new heavy vehicles and the USA has announced its intention to mandate ESC on new motive trucks.

“Australia should gain confidence from this leadership and do the same,” Hart said.

“Australia is a world-leading country in the development of safer and more productive and fuel-efficient heavy vehicles. We need to take the next step; which is mandated ESC for all new heavy vehicles.”

ARTSA and NBTA said they had noted and applauded comments recently made by the managing director of Simon National Carrier, David Simon, about truck rollovers.

“I’ve been purchasing electronic stability on all trailers we’ve bought in the last seven or eight years, really since it’s become reliable and robust in Australian conditions,” Simon said.

ARTSA and NBTA said while retrofitting existing vehicles has challenges and is more costly, some operators still choose to do so.

Justin Keast heads up McColl’s tanker division and operates one of the largest tanker fleets in the country.

He is also chairman of the NBTA and says good operators in the industry have embraced ESC. “It is no longer a debate and our association has supported its adoption for a number of years,” Keast said.

“However there are considerable numbers of operators who are happy to avoid it simply because it adds cost to their business. It is time to level the playing field and ensure that all new trucks and trailers are fitted with ESC.” Hart says former premier of Victoria, John Brumby, led the way in terms of the implantation of ESC. “He forced the motor car industry to adopt ESC for cars. He simply said, if a car was sold in Victoria, it should not be registered unless it had ESC and side curtain airbags,” Hart said.

“It took a very short space of time before all states and the Federal government followed. We need one Premier to stand up and say the same for heavy vehicles, not just tankers.”

The two chairmen say that ESC with rollstability response should be mandated on new vehicles within 18 months. logisticsmagazine.com.au

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3PL

Outsourcing transport to overcome delivery problems Delivering to customers can be a costly diversion to a company’s main business.

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hen paper bag manufacturer, the O’Kelly Group, considered outsourcing its delivery transport, general manager Sarah O’Kelly was caught between running their own transport as they always had and moving to a more modern approach of doing business.

Previous generations of the company, established in 1948, were hesitant about outsourcing but O’Kelly said the company needed to consider more flexible approaches to transport.

O’Kelly said that her father and grandfather’s generation would have been worried about loss of control when outsourcing. This time the manufacturer, operating one of Australia’s largest paper bag manufacturing facilities at its Dandenong processing plant, decided to start small.

O’Kelly engaged national transport company Ontime Group to provide one driver and vehicle around five years ago. Over time this has increased to four, and occasionally more during busy times.

“It was a big decision because the company had managed its own transport for about 60 years. But we put one driver on and it went really well so we gradually increased our commitment,” she said.

Delivery demands are high and constant – it has four to five trucks conducting 750 deliveries a week, close to 40,000 per year. Product includes paper bags, both flat and satchel, which are used for fast food, bottle bags, mushroom bags, grease-proof sheets and more.

The company is also a distributor of other products in the fast food

12 | Logistics&MaterialsHandling April 2014

container range such as coffee cups and plastic containers. But paper bags account for 40% of business.

O’Kelly says that outsourcing transport has saved costs but that some benefits would be hard to quantify.

“There is a saving but it was never about that for us. It was about the cost of interruption to the business, and it’s hard to quantify that.

“The flexibility would have a financial benefit but it’s not always easy to put a number on it.

“When running your own fleet you’re dealing with vehicle costs, breakdowns, maintenance.

Something could go on a truck and you’re up for $2,000. But then you don’t have access to the vehicle either so you need to cover by short-term leasing a vehicle.”

The biggest benefit is flexibility to manage resources, according to O’Kelly. She says the increase in control was an unexpected benefit and contradicted her initial worries about outsourcing.

Having regular back-up drivers on standby covers absenteeism and spikes in demand. “We have one driver who has been with us for years. He stayed on with us when we switched to Ontime, but has unfortunately had to take four months sick leave this year. So we used an Ontime back-up driver during that time and have been able to keep the position open for our driver when he recovers and returns.”

Public holidays were always a problem previously due to the backlog of orders that weren’t able to be delivered on the day. But O’Kelly says it’s now solved by booking extra drivers either side of the holiday.

For a period of time O’Kelly has

added an extra driver one day a week to manage a slightly increased load. “We can add a driver easily, which is important for growing our business. But doing it ourselves, the capital investment to add even one driver is huge.”

Ontime’s drivers are managed through one contact point. “They are part of our team. We treat them like employees. They wear our uniform, they are here every day. We can’t have couriers doing their role,” O’Kelly said.

Delivery transport is also a day-to-day issue for Plyco, an independent Australian manufacturer, distributor and retailer of timber-based panel product. Plyco has a small plywood processing plant where it can produce low volume, specialty orders for boat builders, cabinet makers, joinery, musical instruments and other requirements.

The business is growing strongly and conducts approximately 50 deliveries a week to its customers.

For transport Plyco uses a combination of its own small fleet and an outsourced component, consisting of a Tautliner managed

by Ontime Group.

The decision to partially outsource the delivery fleet came down to reliability, according to business owner David Garvey.

He said customers in joinery shops and factories run tight schedules and can’t afford deliveries being late. “There has been a slight cost saving but reliability was the main thing. It’s a timesensitive product and we risk losing customers if we are late too often.”

But he said the company was having issues getting and keeping reliable drivers on that delivery run.

“We had issues replacing them on sick days. We would either have to draft someone from the warehouse or if we were really desperate I would have to do it.”

Garvey said that absenteeism had effectively been solved by outsourcing, as the onus is on Ontime to arrange suitable replacements.

The result is more reliability and efficiency.

“Deliveries are now more regular, and having access to a Tautliner has improved efficiency because it means we can deliver in any weather conditions, whereas previously with an open tray we couldn’t delivery in heavy rain.” logisticsmagazine.com.au

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bulkhandling

Manitowoc launches new automated counterweight system The new variable position counterweight is a game changer for the cranage industry.

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here’s a couple of brand new cranes on the scene this year, and it looks like a game-changer.

Manitowoc have been leading the way in mobile, luffing pin-jibs for some time, but a simple idea due to be shown off at CONEXPO 2014 is going to make a big splash in the construction game.

Two new cranes, the MLC300 and MLC650, are equipped with a wholly unique feature that Manitowoc calls Variable Position Counterweight, or VPC. The idea is as simple and selfexplanatory as the name, but the implications are massive, and could completely change the expectations that cranes and rigging co-ordinators put on set-up time and ground space requirements.

The VPC system automatically 14 | Logistics&MaterialsHandling April 2014

positions the counterweight for the requirements of the lift, sliding along the rotating bed, altering the counterweight moment to optimise the forward moment of the boom.

In short, the crane’s counterweights are mounted on a track so they can slide backwards and forwards, and all of this takes place automatically, in response to changes in the angle of the boom.

The advantages of this system include reduced ground preparation, lower ground-bearing pressure and less counterweight to carry around without sacrificing capacity.

Ultimately, crane technicians will not have to transport or install as much counterweight as usual, compared with a traditional configurations.

In fact, aside from the transport costs, and the cost of the counterweights themselves, there is also a massive saving in the amount of time needed to change the counterweight configuration.

Rather than removing or loading up on counterweights to suit a particular lift, the VPC simply adjusts itself to suit the lift, which saves on time, reduces the risky handling of counterweights, the amount of labour require to complete the changes, while maximising the capacity of the crane beyond what could be achieved with traditional counterweight configuration.

With interchangeable left and right side counterweights, the counterweight boxes are also designed to be common across multiple crane platforms.

Manitowoc crawler crane senior vice president John Kennedy said the VPC system is game-changing technology.

“This new technology will have a significant impact on the lifting industry, as it enhances crane capacities, reduces mobilisation time on the job site, and in the end, saves customers a significant amount of time and money.”

The MLC300 is a 300 tonner, which comes with 96 m of boom and has the option of a fixed jib attachment of 30m. A 96m luffing jib can be added to extend the boom radius to 144m.

The MLC650, naturally, has a 650 tonne capacity with 104m of main boom to which a 30m fixed jib can be added. A 101m luffing jib can be added for a maximum 157m boom radius. logisticsmagazine.com.au

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bulkhandling

Driving in a new direction: GE launches new LHDs The underground mine is transforming.

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peaking to GE of collision avoidance systems ergonomics and safety in the LHD’s Mining’s Geoff Knox, company Infotronix. design and that “the driver operates he told Logistics and One of its latest developments in the LHD facing forwards, so we’ve Materials Handling the underground mining sector is a built the operations and interface that underground mining is very new Load Haul Dump (LHD) Loader, around that design”. prospective, which is why it has which it launched to the market GE mining stated that the been making major inroads into the at the China Coal & Mining Expo operator’s cabin can significantly sector. earlier this year. reduce the risk of occupational “Underground mining’s According to GE Mining this new working injury and increase the technological demands are higher LHD “is a safe, purpose built vehicle operator’s visibility than open cut mining and stronger with best practice Human Factor “The LHD features a centre mount certification is required, and our designs”. adjustable height cabin with a new technology is what is setting us One of the major changes has swivel seat to allow the operator apart in this arena,” he said. been the direction the driver faces. to face the direction of travel Knox pointed to developments “This is the first new product and access to the cabin outside such as its sealed battery of this size for us,” Knox told of the articulation zone, which L M0 2 1 4 _ 0the 0 acquisition 0 _ BAC 1 LMH, 2 0 adding 1 4 - 0that 1 - GE 1 0focused T 0 8 :on0 4 : 4 greatly 1 + 1 1improves : 0 0 operator safety technology, and

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Importantly, the new LHD has been built with a Tier 3 diesel engine, for safer underground operation and the minimising of emissions in the tunnels’ confines.

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April 2014 Logistics&MaterialsHandling | 15

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bulkhandling

Self-erecting tower lift system saves time and money A new compact, globally transportable tower lift system is helping to cut costs.

A

self-erecting tower-lift system is being introduced by Enerpac that enables users to build a freestanding hydraulic strand jacking gantry from ground level to a height of 80 metres with a lifting capacity up to 1600 tonnes.

The globally transportable ESET series from Enerpac Integrated Solutions(IS) incorporates proven technologies widely deployed internationally, including Enerpac hydraulic strand jacks used for heavy and complex lifting, shifting and positioning projects.

Developed to reduce transportation and set up costs compared with large cranes, the ESET can be packed into containers for applications throughout various industries including oil and gas, mining and energy, materials handling and ports, construction and infrastructure.

Examples include pressure vessels, processing towers, refinery reactors, mineral processing and distribution plants, oil and gasFPSO offshore modules, reactors, communition mills and large plant and port facility construction.

Richard Verhoeff, integrated solutions manager for Enerpac in Australasia, said safety is a key feature of the ESET, which incorporates a unique self-erecting-mast system.

The gantry is installed on skid tracks, distributing the foot print load for maximum stability while strand jacks are used to position the gantry system longitudinally.

To lift the load, the ESET uses a pair of Enerpac Strand jacks, each with a capacity of 850 tonnes. Depending on the ESET configuration, two or four strand jacks can be used. The load can also be shifted sideways by a transverse

16 | Logistics&MaterialsHandling April 2014

skidding system, also operated by controlled hydraulic power packs.

Safe management of the ESET is optimised by two advanced PC-Control systems. The primary system, managing the mast lifts from each corner, controls a precision lift rate averaging three metres per hour within a synchronous tolerance of less than 3mm.

The second system is Enerpac’s Smart Cylinder Control (SCC) control system, which is standard on all strand jack systems and which synchronises the motion of the strand jacks.

All power packs and control-systems can be powered by a single 100kW generator.

Straightforward installation Installation of the ESET series is straightforward, Verhoeff said.

Four lift-containers are positioned at ground level, one for each mast. Inside each container there is an automatic hydraulic lifting mechanism, which lifts the mast barrels in increments of 900mm.

Strength is conferred by octagonal profile

mast barrels made from S690Q steel precision fabricated by robotic technology to maintain stringent quality, strength and dimensional requirements.

While mast stability is achieved by a highstrength lightweight bracing system installed once the barrels are extracted above the lift container level.

“The ESET can be supplied in various capacities and heights and built with standard modular components, enabling a flexible solution to future project demands,” Verhoeff said.

The new ESET is part of the technology range of Enerpac Integrated Solutions, which is dedicated to lifting, shifting and manoeuvring some of the world’s heaviest and most challenging objects and structures.

IS technologies include PLC and SCC (Smart Cylinder Control)-controlled synchronous lifting systems, one operator can control operations such as multi-cylinder lifts, weighing and determination of the centre of gravity of heavy objects. logisticsmagazine.com.au

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warehousing

Mammut raises logistics performance with new distribution centre Mammut recently celebrated its 150th anniversary with a new 25 million EURO distribution centre (DC) at Wolfertschwenden in Germany’s Allgäu region, 12km south of Memmingen.

I

n the mid-90s, Mammut had a turnover of around 30 million Euros. Today Mammut’s turnover is more than 185 million Euros.

Accordingly, its logistics requirements have increased substantially over the years, with the company’s distribution centre already having to move twice since its German business was established in 1987.

Mammut previously operated two main warehouses in Europe – one at Seon in Switzerland and one at Memmingen in Germany.

“By 2009 it became clear our warehouses were too small and we started investigating a new central distribution location in Europe,” explained MSG’s chief supply chain officer, Josef Lingg.

“Since about 70% of our turnover is generated in the EU, we opted for a location directly on the A7 in Germany. In addition to locating the DC on an optimal traffic route for distribution and its proximity to Switzerland, the availability of our experienced logistics staff in Memmingen was an important factor,” he said.

In late 2009/early 2010 Mammut began working on a concept for a new manually-operated DC, which included renting a three-floor, multi-functional logistics building with a total area of 38,000m2.

However, projected high operating costs for the DC forced Mammut to revisit the concept before proceeding.

concept against part or full automation.

“Dematic has earned a good reputation in warehouse technology with excellent order picking and handling services, and presently justifies its market lead in the area of shuttle technology,” said Lingg.

Dematic analysed Mammut’s inventory and order profiles during average and peak seasons, forecast turnover and volume growth up to 2015, and also took into account Mammut’s desire to pick and pack according to item type.

A new logistics concept was developed with a highly automated solution clearly delivering the optimum combination of return on investment (ROI), performance and operating costs.

Dematic’s automated DC concept

reduced the space required for the new DC from 160,000 m3 to 130,000 m3, which enabled Mammut to lower the total investment in buildings and logistics from 27.5 to 25 million Euros.

“Construction costs could also be reduced from 22.5 million Euros to 15 million Euros,” Lingg added.

As well as reducing fixed costs, Dematic’s automated DC concept also significantly reduced operating and labour costs.

Dematic’s solution also minimises energy use, with only minimal heating and lighting required in the 90,000 m3 Multishuttle warehouse.

From signing the contract in May 2011 to the scheduled commencement of operations on November 1, 2012, Dematic

only had 17 months in which to implement the new DC.

Refreshing the supply chain Mammut took the opportunity presented by building the new DC to optimise its entire supply chain and, with its suppliers, to implement a new uniform packaging concept.

Cartons with snap-on lids in two basic sizes – small (400x600mm) and large (800x600mm) – are geared to the new system,eliminating the need for trays or bins. After picking, the cartons can also be reused for shipping, saving around 200,000 cartons per annum.

Key elements of the DC include: Inbound goods: Stock is typically received in shipping containers

A cost-saving, intelligent logistics solution In March 2010 Dematic was given the task of checking the manual 18 | Logistics&MaterialsHandling April 2014

logisticsmagazine.com.au

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warehousing

and unloaded onto a telescopic conveyor, where carton weights are automatically checked for accuracy.

Rapid Store replenishment warehouse: All cartons are initially stored in the six-aisle, 140,000 bay replenishment warehouse, which has a total of six RapidStore SRMs capable of handling two small cartons at a time, and can store or retrieve cartons up to three deep per bay. Items required for picking are moved from here into the Multishuttle warehouse.

The warehouse is also utilised as temporary storage for pre-labelled customer cartons, which can be cross-docked directly to the shipping area.

Multishuttle picking warehouse: The heart of Mammut’s new DC is the four-aisle Multi shuttle picking warehouse with 12 storage levels providing a total of 20,000 bays.

Each storage level has its own shuttle and each aisle has its own lift, so that put-away and retrieval can be handled simultaneously on different levels, with up to 600 double cycles per aisle per hour. A feature of the system is the first use of Dematic’s new lighter, faster and logisticsmagazine.com.au

more economical Multishuttle 2.

“As a result of the new control,communication and sensor concept, the Multishuttle 2 can process the cartons directly without the use of additional trays, and this was an important requirement for Mammut,” Dematic’s Project Manager, Udo Rogowsky said.

Within the Multishuttle system, only items required for orders are kept in stock, which enables the system to be half the height of the replenishment warehouse. Because of this it was possible to house the Multishuttle system on the upper floor, enabling additional space on the ground floor to be kept free for inbound goods and shipping functions.

Inventory staging buffer: A sequencing tower pre-sorts cartons from the Multishuttle system and conveys them in the required order assembly sequence to nearby order picking stations.

“This enables heavy items to be sorted first and then the sorting of clothes according to size and colour, so that they are shelf-ready when they arrive at the store,” Rogowsky said.

Goods-to-Person (GTP) picking: With the aid of a pick-to-light (PTL) system, up to three orders can be processed simultaneously at each of the four order picking stations. PTL displays indicate how many items must be removed from each carton and put to the relevant orders.

Approximately 400 order lines with an average of three items per line can be processed at each picking station each hour.

Value-added services stations: Some orders must be processed at the value-added services stations, which are situated beside the picking stations and are connected to the conveyor system. Here special tags or customised label sizes and label designs are attached to the goods,coat-hangers are removed or special cartons used.

Packing stations: Orders received by 1.00pm are processed the same day and assembled for shipping.

From the picking station, the order goes down by lift to four packing stations on the ground floor. Here the operators insert consignment notes and other shipping documents into the cartons, and label the sealed cartons.

Outbound goods: Cartons are then either conveyed to a palletising station to be shipped by a freight contractor, or to one of two telescopic conveyors in the outbound area for packages going to Germany and Switzerland.

Dematic’s system scores top marks Dematic’s Material Flow Controller (MFC) receives transport orders from Mammut’s Warehouse Management System (WMS), calculates the route distances, and generates and manages transport orders according to priority, sequence and status. In addition, MFC controls the conveyor system and manages system operation, with any bottlenecks, disruptions and system capacity issues considered when orders are issued.

Dematic’s Logistics Cockpit gives the warehouse manager information about the current state of the entire system, and provides the necessary tools to supervise the processes and functions efficiently.

“It was a great achievement that we could actually start operations with such a complex project on the exact date,”Lingg said.

April 2014 Logistics&MaterialsHandling | 19

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technology

Australian wholesale distributors lag behind in E-commerce adoption A study reveals some businesses are not taking full advantage of online opportunities.

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esearch has found the Australian wholesale distribution sector is lagging behind in e-commerce adoption, with only 10 percent of companies currently able to receive orders directly over the Internet.

The study, commissioned by NetSuite, shows that despite strong optimism about their prospects for growing the e-commerce channel, with almost 75 percent of businesses viewing it as an opportunity, the study conducted by Frost & Sullivan has indicated just how unprepared wholesale businesses are to handle this growth.

“For wholesale businesses, e-commerce is both an opportunity and a challenge,” said Mark Dougan, managing director for Australia and New Zealand for Frost & Sullivan.

“It offers a way to build closer and more direct relationships with the end customer, the ultimate consumers of their products, but also presents both strategic and operational challenges. The strategic challenge largely lies in the risk of bypassing long-established distribution channels. Our research identified that the main operational challenge is in linking the e-commerce front-end to existing internal business systems.”

The sponsored survey of 102 Australian businesses in the manufacturing and wholesale distribution sectors was carried out by Frost & Sullivan in September 2013, to understand the importance of the Internet as a channel for their future business success.

It revealed that businesses in these sectors see the opportunities and benefits that e-commerce can offer, particularly convenience for customers, reduction in distribution costs and linking customer orders directly with central business systems.

While 76 percent of respondents envisage that customers will increase online ordering over the next few years, ordering direct from their websites is much less common than in the retail sector, with most currently only receiving orders via e-mail.

However some businesses still identify a number of challenges that are keeping them from adopting e-commerce, including losing

20 | Logistics&MaterialsHandling April 2014

direct relationships with B2B customers, system integration issues and the feeling that they need to offer lower prices online.

According to Frost & Sullivan, while only a small percentage of B2C consumers are able to order directly from wholesalers and manufacturers online, more than 50 percent of Australian manufacturing and wholesale businesses now place orders directly with suppliers online.

Over three-quarters of businesses expect to increase their online ordering from suppliers, citing quicker and easier ordering processes, access to a wider range of suppliers, less paperwork involved and lower prices than other channels as the top reasons.

Social media broadens communication channels with customers The Frost & Sullivan study indicates that adoption of social media as a communication channel with customers is increasing, with 30 percent of manufacturing and wholesale businesses now having a social media presence.

Looking at manufacturing specifically, while take-up of social media is low compared to other sectors, it has doubled in the past three years to almost 15 percent. For both sectors, however,

telephone and e-mail remain the dominant communication channels.

“Social media is becoming an increasingly important platform for customer communication and engagement,” said Dougan.

“Businesses in the manufacturing and wholesale sectors are increasingly recognising the benefits of establishing direct communications with their end-consumers through social media.”

Integrated software platform overcomes challenges According to the research, a major challenge faced by many Australian manufacturers and wholesale distributors with a web presence is a lack of integration between their web front-end and internal back-end systems, with less than 20 percent having automated links. Respondents cite a lack of integration as a major issue for exploiting e-commerce, followed by a lack of systems to service customers that cross between online and other channels, as well as a lack of systems that connect inventory to online sales channels. Without a unified software solution, these businesses face difficulties in maintaining a consistent brand experience in areas such as customer support, pricing, as well as increased operational costs to run and maintain each channel. logisticsmagazine.com.au

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forklifts

How to get the most out of your forklift fleet Warehouses are finding greater efficiencies by tracking their forklift fleets.

I

n the world of forklifts there haven’t been any groundbreaking changes in recent times.

All the major players, Toyota, Crown, and so forth make good machines that are quite capable of doing the job they are expected to do.

So where does that leave companies who want to improve their forklift fleets and improve their bottom lines? Logistics & Materials Handling caught up with Andrew Satterley, Adaptalift Hyster’s CEO, to hear his answers to this question.

“I think it’s more been around some of the offerings that would come with the forklifts,” Satterley said.

“It’s the subtle things that are having the biggest impact for all the players in this industry.”

For Adaptalift Hyster the focus has been on fleet management.

“Our tool is called ForkTrack and what that provides to the companies that use it and to the operators is a complete fleet management and L M Hsystem 0 4 1 4for_ the 0 0equipment,” 0 _ D M F Satterley 1 2 0 1 4 safety said.

For example, it ensures operators put their seatbelt on before they can start operation; it records who is using the equipment at any given time (via ID cards); and it causes the equipment to shut down on impact.

On top of that, it includes advanced features such as a digital weight indicators, speed and zone control, Lift/tilt Lockout, Overload lockout, etc.

“It even has a really cool feature – the -automatic 0 3 - 1 0email T 1 4alert. : 4 It 6 will : 4 9send + 1 emails, 1 : 0 0

doors for ALL industry

depending on the event, to whoever is set up to receive them,” Satterley said.

“The recipient will be informed that the forklift has had an accident; it’s in lockout mode because the weight is too heavy; and so on...”

According to Satterley, such systems are where the real advances in forklifts are. Systems like ForkTrack are having the largest impact for large warehouses right now.

By way of example, Satterley pointed to the contract Adaptalift Hyster won with Coca-Cola last year.

“One of the reasons we won the Coca-Cola contract this year was based around telemetry, and it’s become a big topic for these big warehouses,” he said.

“And we’ve been able to reduce the amount of forklifts Coca-Cola have with this product. So we’ve been able to say – ‘We can make it more efficient. You don’t need as much equipment. You just need to use it more effectively.’ ”

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April 2014 Logistics&MaterialsHandling | 21

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materialshandling

Rio Tinto benefits from clever conveyor innovation A 2km coal conveyor system that combines engineering innovation and efficiency been completed by the Ellton Group for Rio Tinto’s Hunter Valley Operations.

T

he 1400 mm belt conveyor system rated at 2400 TH – driven by groundmounted Bonfiglioli Power Pack drives – includes an overland conveyor and a skyline stacker conveyor system that eliminates the previous need for heavy trucks to transfer coal from another load out facility during peak production.

The unique conveyor design overcame numerous environmental and structural challenges as it traverses reclaimed and subsidence-prone land to deliver high volumes of coal to an existing stockpile facility through a cost-efficient design that incorporates recycled previous structures.

“One of the many unique aspects of the design was the complete incorporation of an existing skyline gantry system contained within the new structure,” managing director of the Ellton Group, Mark Elliot said.

“The old gantry had a tripper running through it. We built our new, higher capacity structure around the existing tripper gantry, running the conveyor in the opposite direction but sharing a radically improved and strengthened structure that easily and safely handles higher conveyor loadings but is designed to minimise additional mass and wind loadings.

“I think one of things that impressed Rio Tinto was that we didn’t attempt to impose standard solutions on their unique technical and site issues.

Elliot said his team worked in consultation with Rio’s operations staff and their consultants, and evolved numerous options that made good use of existing infrastructure while observing the company’s rigorous safety and environmental standards.

Elliot said his company recovered and re-used the old gantry structures, which were stripped, refurbished, painted and refitted to new standards and incorporated in the elevated stages of the overland conveyor. In addition to saving money and avoiding waste, he says the project cleaned up the entire site where 22 | Logistics&MaterialsHandling April 2014

the structures were previously located.

“The benefit of this innovative approach was clearly seen in the way in which we repaired and strengthened existing trestles and piers to withstand new loads, for example, providing a solution for less than half their expected price,” Elliot explained.

A further initiative implemented by Ellton saw the areas traversed by the overland conveyor protected by civil works including bunding, side dish drains, channeling and settlement ponds.

These works separate and redirect clean water run-off from the surrounding landscape to avoid possible contamination and capture water emanating from the conveyor path, directing it to one of several dirty water settlement ponds constructed along the route. By containing run-off and run-on, recycling is optimised and contamination of the environment is avoided.

To minimise additional wind and mass loading

on the existing structure, Ellton adopted a “wrap around” gantry design to support the new conveyor and tripper. The gantry design had to be as light as possible and still allow the existing tripper to operate inside the old gantry both during and following construction.

Elliot said the use of innovative Bonfiglioli Power Pack fully coupled drive combinations, also saw new ways of thinking implemented at the mine site.

Engineered by Bonfiglioli for ease of installation, rugged service and low maintenance in materials handling and process applications, the drives and take-ups were mounted at ground level, rather than with elevated drives and vertical take-ups, for ease and safety of maintenance.

“A problem with off-ground mounting is that access is difficult and it is hard to isolate the belt and remove the energy load from within it,” Elliot explained.

“With our on-ground concept, it is simple and safe to de-tension the belt and remove the stored energy, thus enhancing safety. The hazards associated with isolating suspended gravity weights are removed. The design – which reflects our experience in underground mining – also provides better and quicker access for maintenance.”

Elliot said the approach taken for at Rio’s mine is an example what can be achieved when not hamstrung by outdated approaches to conveying systems.

“That’s the sort of thing you can do as a younger, nimble and innovative supplier,” Elliot said.

“While we have had plenty of experience, particularly in the Hunter Valley, we are not bound to old ways of doing things or regimented thinking that says we have to tear down everything that’s already there and start again. As a company committed to efficiency, sustainability and minimising the impact on the environment, I think Rio Tinto were impressed by our close attention to their wishes.” logisticsmagazine.com.au

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logisticsoperations

A new choice in fleet management With petrol prices soaring, all eyes on are focused on how to reduce fleet vehicle running costs.

A

global provider of fleet management solutions for commercial vehicles delivered as softwareas-a-service, Fleetmatics recently opened an office in Australia to service fleet-based businesses.

The timing of the launch comes as petrol prices throughout the region continue to climb with local economists noting the start-of-year price increase is the biggest the nation has seen since 2004.

The company has nearly ten years experience in providing workforce productivity solutions for commercial fleets and provides businesses with fleet control solutions.

LFleetmatics M 0 4 1 4 _says 0 0its 0 _ ADA 1 20,000-

plus customers are empowered vehicles worldwide, Fleetmatics to significantly increase says it helps reduce operating mobile workforce and fleet and capital costs while boosting productivity, safety and security, revenues for fleet-driven businesses while decreasing costs related in virtually any industry. to unauthorised use, payroll “Officially expanding into discrepancies and more.

Australia was a natural move 2Currently 0 1 4 - installed 0 3 - 1 2inTover 1 0 417,000 : 4 3 : 1 for 4 +Fleetmatics 1 1 : 0 0 on the heels of

HYSTER and

logisticsmagazine.com.au

our August 2013 acquisition of Connect2Field, a Sydney-based provider of field service software,” said Fleetmatics CEO Jim Travers.

“The launch comes at the same time as our expansion into the Netherlands, both of which deliver on our goal to continue to grow the business via global expansion and new partnerships.”

Darren Linney, CEO of Formway Group Ltd, a Queensland-based metering company said he chose to use Fleetmatics because of the level of visibility and control its solutions involve.

Fleetmatics currently has locations in Ireland and the UK, as well as several offices throughout the US.

are registered trademarks of NACCO Materials Handling Group, Inc.

April 2014 Logistics&MaterialsHandling | 23

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inventory

Customisable inventory solution This family owned and operated business needed a one stop solution to manage their business.

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in United is a family owned and operated, small business that supplies industrial and hydraulic hoses, fittings and valves.

The cornerstone of the business is their extensive inventory – 11,000 line items, with up to 4,000 in stock at any one time. The business also prides itself on its exceptional customer service and ‘can do’ attitude. For example, it’s not unusual for customers to want a single order to be sent to multiple delivery addresses and have invoices sent to multiple email contact points as well.

While these requests are very reasonable, Win United found themselves in a situation where their IT systems didn’t have the flexibility to meet customer requests and deliver the level of service they wanted.

Sales manager, Lennie Wiggins, said the business required a new, custom-built system.

“We were using a Cloud based accounting package together with a stand-alone CRM to manage the business, but found that within just six months, we had already outgrown the system and become frustrated with the lack of flexibility,” Wiggins explained.

“In looking to change systems, I knew that I still wanted a Cloud based solution, as being able to access the system from anywhere was critical, but I wanted a solution that was a complete package, not multiple systems bolted together. I also wanted to be able to customise the system so that it worked according to the way our business works.”

24 | Logistics&MaterialsHandling April 2014

The switch to JCurve accounting After speaking to an expert who recommended that Win United consider JCurve, the company decided to make the transition at the start of a new financial year.

The implementation and transition lasted three weeks, and while Lennie says there were some challenging times, the process also afforded them a great opportunity to learn the new system.

Since implementing JCurve, one of the biggest improvements has been the time taken to complete purchase orders, Wiggins said.

“Our purchasing processes are so much quicker now – as much as 50% faster.

“Other processes like bulk invoicing, receiving stock and sending goods out have improved as well. The ability to select multiple sales orders and update their status is a great time saver too.”

More broadly, the business is also benefitting from the improved operational processes. Quotes are converted to sales orders, sales orders are picked, packed and shipped, and then invoices are emailed automatically. The automatic issuing of invoices has mitigated any risk of invoices not being sent, and has improved cash flow with invoices being sent as soon as the goods are shipped.

More improvements via CRM and Customised Reporting Win United has also taken advantage of the

CRM functionality in JCurve and uses it to record customer visits and calls. The progression of customers is also recorded, with account managers being able to see when a contact transfers from being a prospect to a customer. Customers are then tracked on a weekly and monthly basis to understand if the company’s marketing efforts are working, and identify any changes and trends in customer behaviour.

As well as typical reports such as Sales to Date, Outstanding Quotes, and Total Inventory, Wiggins says the personalised dashboards are a stand out feature.

“For example, our guy responsible for receiving can look at his dashboard and know exactly how many orders he needs to receive that day,” he explained.

As a manager, Wiggins has a customised dashboard so he can see, at a glance, sales by state, quotes to close, customer profitability summary, monthly new customers, monthly receivables, and monthly inventory.

Team performance is also managed via a dashboard showing how staff are tracking against their VIGs (very important goals), such as the number of outbound telemarketing calls they’ve made.

“In comparison to other systems I know, JCurve is just so clear and easy to use. Where other companies have to use multiple systems to get the information they need, I’ve got it all in one system,” Wiggins said. logisticsmagazine.com.au

LM0414_000_MAT - 1 2014-03-12T10:54:58+11:00 LMH1404MH_Layout 1 10/03/14 3:35 PM Page 1

A Safer Way to Unload Containers & Trucks Destuff-IT and Restuff-IT are PLC controlled ergonomic assist devices that help workers to manually load and unload products into containers and trailers.

The units use an on-board drive system to move in and out of the containers and have a pivoting conveyor, with a high grip belt. This can be effortlessly guided up and down, left or right to place a product in the desired position & a height adjustable platform puts operators in the best ergonomic position.

This means workers are less fatigued and the risk of muscle strain and injury from repetitive lifting, twisting, carrying and overhead reaching is significantly reduced. The innovation is based on a unique blend of design concepts, a firm grasp of ergonomic principles and the implementation of technology to address this global problem. Productivity and efficiency is enhanced through optimized worker positioning. Handling movements are minimised, contributing to more throughput and greater handling capacity.

These devices are designed for demanding, continuous multi-shift operations and to be integrated with extendable or flexible conveyor systems. The selfpropelled machines have an integrated DC powered dual travel drive and steering system capable of negotiating dock leveller slopes and transition plates while driving in and out of containers or trailers. This means it can be easily and quickly moved to another dock position and is capable of towing host conveyor sections. Users can achieve significant ROI savings through productivity gains, reduced injuries, enhanced dock utilisation and integration with existing conveyors. In a recent one-week trial, one prospect was able to see an increase in case rate of 59 percent and a reduction in overall labour of 49 percent.

Destuff IT

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Preventing injuries … Destuff-IT and Restuff-IT ergonomic assist devices are the safer way to load containers and trailers.

A demonstration video is available on our website or on YouTube: http://www.youtube.com/watch?v=AD0xjOfnN9A&feature=youtu.be

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inventory

Revolutionising online shopping for modern customers A new innovative method of collecting items bought online has made its mark in Australia.

T

he Internet has revolutionised the way people purchase goods.

However, when it comes to the collection of these items, customers are often left feeling frustrated and disappointed. The lack of alternative and convenient delivery options, as well as the challenges of returns and services can tarnish a customer’s online shopping experience. Until now.

Pioneered by TZ, the A.D.A.M. Parcel Locker Network is the first fully automated end-to-end parcel locker network offering of its kind in Australia. Designed to cater to time-poor, budgetconscious modern lifestyles, these interactive lockers give customers a convenient, secure and cost effective way to collect their online orders.

Through partnerships with select e-merchants, e-commerce service providers and courier and logistics players, the TZ A.D.A.M. Parcel Locker Network will allow customers to have their parcels delivered to a convenient locker location of their choice. Customers are notified by email or SMS when their package is ready for collection and to guarantee convenience, the lockers are accessible 24 hours a day, 7 days a week.

TZ approached Dexion in 2012 in search of a supply partner with specialist capabilities in manufacturing high volume metal systems. To ensure the effective development of new parcel locker infrastructure, it was essential that the lockers be of a high quality, extremely durable and capable of storing parcel items safely and securely.

In designing the lockers with TZ, 26 | Logistics&MaterialsHandling April 2014

Dexion understood that customer confidence is paramount. The lockers therefore incorporate both internal and external elements that are robust, safe and weather resistant. In addition, the lockers can be configured to suit any space and are available in a range of sizes, ensuring complete versatility.

As the demand for parcel delivery services continues to grow in tandem with e-commerce, some of Australia’s well known retailers are starting to tap into the services provided by TZ and its partners.

According to Dexion’s national sales manager, Michael Cumner, parcel lockers offer Australian shoppers true flexibility. With six installations already completed at shopping centres, commercial office towers and service stations around

the country, and another eighteen being installed soon, Cumner believes that interactive lockers are the way of the future.

“Whether servicing corporate, residential or community environments, parcel lockers provide a seamless end-to-end solution for the changing lifestyles of modern consumers. Shoppers want to know that they can access their goods when and where it suits them. It’s very exciting to be part of a network that’s shaping the future of online shopping,” Cumner said.

“The demand for interactive lockers is growing at a rapid rate, both locally and internationally.

We are also supporting TZ with its smart parcel locker solutions for Singapore Post, Poste Italiane and Post Indonesia. We see the potential

for a significant number of new locker projects over the next twelve months.”

Dexion is also working closely with TZ to support the rollout of A.D.A.M. parcel lockers to new locker locations across the east coast of Australia.

The A.D.A.M. Parcel Locker network is unique in that it benefits all stakeholders. Online retailers are able to enhance their customers’ experience with new delivery services; property partners enjoy increased foot traffic and the potential to leverage exposure through kiosk advertising; and finally, consumers have complete flexibility to choose where and when they collect their parcels, as well as how they return goods and access new services. logisticsmagazine.com.au

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inventory

Updated mobile device helps retailers A mobile handheld computer for retailers gets a technology upgrade for faster data processing, barcode scanning and decoding.

I

n a retail department or to Honeywell’s popular clothing store, the inability Dolphin 6100 scanner: it to accurately track inventory is light, pocket-sized and can result in reduced profits looks good on a retail and unnecessarily dissatisfied floor. On the inside, customers, not to mention the however, the Dolphin inability to help online operations 6110 has upgraded fulfill orders. technology, including Honeywell has announced the an 800 MHz processor, Dolphin 6110 upgraded mobile updated barcode scanning handheld computer, which is and decoding capabilities, purpose-designed to help solve increased memory and these challenges, is now available a broader WLAN radio to Australian retailers. The device frequency range. helps retail workers track inventory, “Retailers are increasingly conduct merchandise audits and turning to specialist technology price look ups, and assist customers. solutions that allow them to boost On the outside, the Dolphin 6110 productivity and traceability of A D _ computer L O G S I looks M O Cidentical T _ 0 9 . p d their f Pstock,” a g e Honeywell 1 9 / 2scanning 2 / 0 9 , mobile

logisticsmagazine.com.au

and mobility country manager Tony Repaci said.

“The Dolphin 6110 offers Australian retailers the industry’s best scanning and barcode decoding to achieve these goals, “The Dolphin 6110 presents a great option for retailers who look for an easy-to-use device that is future-proofed to ensure the best return on investment.”

Other features and capabilities include full-shift battery performance for reduced downtime and cost associated with pools 4 of : spare 0 7 batteries; PM 2.8 inch VGA

touch screen display and 28-key shifted alpha-numeric keypad and an ergonomic design with an IP54 rating, making it easy to use and rugged enough to withstand drops on concrete.

The new technology also encompasses imaging technology for intuitive and efficient reads of 2D barcodes, including poor or damaged barcodes, and barcodes found on challenging surfaces like mobile phone screens. It also has the ability to integrate with Honeywell’s Remote MasterMind device management software, which gives IT administrators the ability to manage multiple mobile computers and other devices across multiple sites.

April 2014 Logistics&MaterialsHandling | 27

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factorymaterialshandling

After-purchase service lifted A Sydney business says it is benefitting from after installation service from its chain hoist provider.

A

major industrial user of chain hoists, ANZPAC, says its Sydney facility has benefitted from the adoption of Konecranes’ service backup and technology designed to enhance safety, reliability and efficiency in factories.

The company depends on chain hoists for its light lifting operations, deploying more than 20 hoists serviced by Konecranes, including one of the first of Konecranes’ next generation Konecranes CLX chain hoists to go into service in Australasia.

ANZPAC, an Australian packaging company which has been operating L MSmithfield H 0 4 1 4 site _ 0 since 0 0 _1992, PRI at its

switched to Konecranes service maintenance identification, last year, when it also installed the reporting and communication from 500kg CLX as part of an ongoing the technician at completion efficiency enhancement at the site. of the work has greatly helped “Their service has been second in building this relationship to none,” says ANZPAC engineering since taking on ANZPAC’S crane manager, Chris Martin. maintenance in August 2013,” “They come in on time, do their De La Mare said. service and leave. They blend in so “We are also proactive in well with our operation that you’d consulting with the client about hardly know they were on site.” efficiency and safety opportunities, Konecranes service contract liaising constantly with our manager Peter De La Mare says site contact and the safety and efficiency values advising of shared by ANZPAC and Konecranes possible solutions have helped to build a strong to many onsite relationship. concerns. As the “Our breakdown response world’s largest 1 2attention 0 1 4 - to 0 preventative 3 - 0 5 T 1 6 : 1 2 :crane 5 3 + 1 1 : 0 0 time, service providers – with more than 420,000 cranes of all brands under service contract EXPL OR B worldwide – we can provide global STO RAND N E OUR REM E technology leadership in addition to ASTAW SITE .COM our strong local knowledge.” .AU ANZPAC places a high priority on safety, reliability and efficiency, FOR THE LOGISTICS & which it says was a driving force HANDLING INDUSTRIES behind the company’s decision to install the CLX hoist and become one of the first in Australasia to Inventory introduce it to service.

Control Cabinets ANZPAC’s 500kg capacity CLX Make it easy to organise, hoist is part of a range extending find and secure your valuable goods. up to 2.5 tonne capacity that is designed for a longer lifetime, with up to 1600 hours service on DESIGNED AND most models with a full load, and a MANUFACTURED IN AUSTRALIA durable aluminium construction.

Durability of the lift chain is a key element in the CLX’s design for service in environments such as ANZPAC’s, where it is deployed mainly for lifting of gravure Battery Transport Gas Cylinder Relocatable Dangerous & Storage Storage Goods Storage cylinders used in printing presses employed in producing packaging for a wide range of customers across the food, beverage, tobacco and FMCG industries.

1300 134 223 storemasta.com.au The CLX’s patented chain 12517

EFFICIENT, SAFE STORAGE SOLUTIONS

28 | Logistics&MaterialsHandling April 2014

sprocket improves the durability of the hoist chain and the chain sprocket’s transmission has been completely redesigned. While safety functions have been integrated into the standard characteristics of the hoist. For example, the brake and the clutch have been installed on the same axle, which prevents the load from dropping even if the clutch breaks down.

This feature takes the safety of the CLX chain hoist to a new level, says Konecranes.

“Konecranes’ CLX chain hoist is designed to perform in applications where reliability, safety and efficiency are critical,” De La Mare said.

“This is particularly important for ANZPAC, which relies heavily on light lifting chain hoists to load and unload material for their stationed operators.” logisticsmagazine.com.au

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Customised conveyor investments cut energy costs

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Intelligent Drivesystems, Worldwide Services

NORD DRIVESYSTEMS INTRALOGISTIC SPECIALIST Frequency inverter n n n n

Energy saving management AS-Interface on Board Up to IP 66 High quality frequency inverter

With the potential to realise energy savings in the thousands of dollars every year, the decision on what equipment to use as part of a major factory refurbishment is an important one.

B

ruce Granger, general manager with Industrial Conveying, one of Australia’s leading project orientated conveyor companies, says that with the increasing cost of electricity, energy efficiency is becoming increasingly important for his clients and end users.

“Companies are now looking closely at what their energy consumption is, so anything they can do to reduce it is a huge advantage for them,” Granger said.

Granger explained that the refurbishment project in question involved a multi-national manufacturer consolidating one of its Sydney plants, and was a prime example of what can be achieved using customised equipment.

“It was not just energy savings we were able to offer the client, there were substantial savings in installation and wiring costs as well,” he said.

“While the project is in an existing building, it had been completely stripped and refurbished inside with new equipment from us and equipment from other plants.”

Granger said there are two phases to ICA’s part of the project.

“One phase is taking cartons from the plant’s manufacturing cells through an overhead conveyor

system, then carrying the cartons down to a sophisticated palletising system, with around 250m of conveyors in total.”

He said the system has several automated mergers where cartons from four different manufacturing cells travel on the overhead conveyor systems.

“Then they all merge onto one main trunk line which takes the cartons to the palletising system.”

Granger explained that the manufacturer has 30 plus SKUs with two main variations of cartons; one measuring 400mm x 250mm x 200mm with the larger carton measuring 650mm x 300mm x 280mm and weighing up to 20kg.

“While the flow rate through the system is modest at the moment, the system has the ability to be increased when needed as production rates increase.

“We have designed the overhead conveyor system to accumulate via particular types of belts that we use, with the ability to turn the drives off and on as needed.

“From the overhead conveyor systems, the cartons feed down to the palletising unit itself where the sorting system sorts the cartons into various lanes.

The company is using SEW-EURODRIVE electrical equipment with various types of the MOVIGEAR Mechatronic drive

Gear unit

Motors – IE2 / IE3 / IE4

n 2-stage bevel gear units n Unique aluminium housing

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n n n

Lightweight Smooth surfaces Cool surfaces

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High efficiencies Wide voltage range Low waste heat Large power reserves Long service life

intralogistics.nord.com NORD Drivesystems (AU) Pty Ltd 18 Stoney Way, Derrimut, Victoria, 3030 Australia Phone: +61 3 9394 0500, Fax: +61 3 9394 1525, www.nord.com.au Melbourne / Sydney / Brisbane National Customer Service 1300 00 NORD (6673), au-sales@nord.com Member of the NORD DRIVESYSTEMS Group

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DRIVESYSTEMS

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system, which it says is ideal for materials handling systems.

Granger said that the Mechatronic drive system comprises an efficient electric synchronous motor and gear unit with matching electronics in a single compact housing.

“Overall, we are using 56 SEW-EURODRIVE motors on this project; the MOVIGEAR SNI, linked to MOVIFIT field controllers, and MOVIGEAR DRCs. “The MOVIFIT system has allowed us to control up to ten of the MOVIGEAR drives from just one controller, which has significantly reduced our field wiring component and simplified the controls.

“It has also considerably cut our installation times by allowing us to do the pre-wiring of many of the components, such as the photo-electric cells where they are connected straight back to the MOVIGEAR units, in our factory set-up.

“By doing a lot of the pre-installation work and dry commissioning the system in our 30 | Logistics&MaterialsHandling April 2014

Bendigo factory this gives us the considerable advantage of reduced on-site work.”

As one of Australia’s leading project orientated conveyor companies, operating since the mid-70s across a wide range of industries, Granger said this project is a prime example of a customised project designed and built to the client’s specific requirements.

“This project, with its 56 motor system, is just one example of what we can achieve using SEW-EURODRIVE equipment”, Granger said.

“Across the drives, we estimate the current draw will be as low as 20 Amps, whereas if we had designed the project the conventional way the current draw would be much higher, could be up to 60 Amps, and cost the manufacturer considerably more to operate.

“Over the life of this equipment, there will be substantial savings in energy consumption; savings in the region of thousands of dollars every year.”

Granger said the main reason ICA uses SEW-EURODRIVE equipment is its high quality.

“It is very reliable and efficient, plus we get excellent service and back-up. It’s the whole package.”

The technology John Gattellari, SEW-EURODRIVE’s national industry specialist - food and beverage, said the MOVIGEAR drive system is an intelligent device and one every manufacturer should be taking advantage of.

“A systematic development approach was taken right from the start of the design process of the drive system with a very high level of system efficiency, which in turn helps lower energy costs,” Gattellari said.

“The motors comply with IE4 (Super Premium Efficiency) energy efficiency classification, and higher, offering impressive energy savings.

“Depending on the application, the MOVIGEAR drive system offers customers potential energy savings of up to 50%, every year,” he said.

According to the company,the

MOVIGEAR SNI (Single Line Network Installation) also allows simplified installation, which leads to significantly reduced installation and system costs.

In contrast to current decentralised automation technology, which relies on two separate cables for energy and communication, the single line technology deployed with MOVIGEAR communicates over one of the phases of power, reducing the complications and cost of on-site installations.

“This simplified system structure can often reduce the time taken for start-ups from weeks to a matter of days,” Gattellari said.

“With this project, the manufacturer has linked the MOVIGEAR drives to MOVIFIT SNI controllers which have been designed for decentralised installation in the field.

“The MOVIFIT SNI can control up to 10 MOVIGEAR drive units, passing the control information via Ethernet signals.”

Customers are also able to logisticsmagazine.com.au

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optimise a MOVIGEAR unit for different speeds, meaning a reduction in the number of variants required, with the corresponding number of spares required also heavily reduced.

Gattellari explained that when it comes to old and new technologies, the difference is huge.

“With this new technology, the payback is often within two years, as opposed to old technology, which is considerably longer.

“In fact the ROI on this project is expected to be even less than 18 months,” he said.

Gattellari went on to say that as well as providing the conveyor systems for the new section of the plant, ICA is also upgrading other parts of the plant and installing SEW’s MOVIGEAR DRC motors.

L“These M0 2 1 4 _ 0 can 0 0 simply _ BOS motors be -

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plugged into our standard gearbox. gearboxes and put new ones in with In this section of the plant, the the same mountings.” manufacturer didn’t want to change Gattellari explained that there anything mechanically, they just are two variants of MOVIGEAR DRC wanted to lower their energy costs motors available, one with brakes, and improve efficiencies. one without - with both types used 1 2“So 0 1they 4 - took 0 1 off - 0the 7 Told 1 6 : 1 0 : 2 on 6 +this 1 1project. : 0 0

He also said that the MOVIGEAR is a hygienic drive, with no sharp edges and totally smooth.

“It is also fully enclosed with no air, dirt or germ swirls, and with low noise emissions, due to the drive operating without a fan, it is ideal for use in manual work stations.

“The optional HP200 coating is designed so nothing can stick to it, making it ideal for hygienic or ‘wash down’ applications in the food and beverage industry,” he said.

Gattellari reports that more and more customers are taking advantage of the MOVIGEAR drive system, including major global companies such as Coca Cola.

“They have all been very impressed with the system’s ease of installation and the on-going reduction in energy costs,” he said.

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By using SSI SCHAEFER’s storage and racking platforms, usable warehouse storage space can be practically doubled or tripled.

Using standard pallet racking frames and beams to support both picking platforms and live storage beds with hot dipped galvanized floor mesh, the modules can be designed to suit individual requirements. From a simple system where products can be picked to tote, to the more complex alternative with pick to light paperless order picking, in conjunction with a pick to belt operation for high speed case selection.

Multi-tier installations can be created using both steel platforms and raised storage areas which result in additional storage levels which are the same size as the ground floor installations. System can be customized according to individual requirements, and extended as necessary, both length-wise and front-to-back.

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