How Material Handling Solutions Add Value To Your Business?

Material handling is an art involving moving, packing and storing of substance in any form, including the preparation, placing and positioning the material to facilitate their movement or storage. Material handling solutions come to the rescue when the material is moved away from the manufacturing, distribution or office environment. Material handling solutions also helps during preparation for shipment, transportation maybe by sea, air or land, by moving material in and out of carriers.

Material handling in addition to handling of materials in any industry is also significant in terms of cost and overall operations because it is something that is quite common to all the manufacturers.

What are the objectives of material handling solutions?

The main objective of material handling solutions is to reduce production cost and reach the overall goal. While manually transporting heavy loads using your strength alone makes for slow and laborious work. Most people aren’t able to move very quickly while carrying weighty items, furthermore, a person can’t carry as many things at once. Using the right material handling solutions allows you to transport your entire load swiftly and easily.

Reduction in cost

Using industrial trucks are expensive because of the labor cost of operators plus the negative effect on production system’s performance while several units are mixed together in one transfer batch just to reduce the required number of moving trips. A well organized warehouse with the most efficient materials and handling tools will translate into a fewer misplaced items. Employees will waste less time searching for products. This will save you money.

Reduces product loss

No company wants to incur product damage and loss in their warehouse which will decrease the profit margin. Implementing good materials handling practices in your warehouse will go a long way to preventing product damage and loss.

Material handling functions

For the primary function is to select the safest and most efficient material handling services which will help to deliver on time and fulfil the needs. It also focuses on bringing down the overall cost and does plant layout assisting for production machinery. A good material handling solutions functions are:

1. To speed up the movement of equipment, assist with mechanical aids and eliminate manual labor.
2. Reduce the transport involved in production of a material.
3. Optimum use of gravity of movement of materials whenever it is possible.

Increase in capacity

Improved material handling solutions results in increase of capacity by better utilization of space. Improved handling systems can increase the capacity in the following ways:

1. By better utilization of space.
2. By reducing travel space or excessive usage of space.
3. By improving equipment utilization.
4. By faster loading or unloading.

Avoids workspace accidents

Manual handling injuries are awfully common these days. Many permanent disabilities and temporary disabilities can be attributed to workplace accidents due to mishandling materials. The key to avoid this is having the correct equipment and machinery along with a well trained staff. This greatly increases employee retention and lost sick days.

Last but not the least, smart material handling solutions will create a safe environment for your products and employees. An open plan for your warehouse will facilitate easy handling materials while minimizing hazardous conditions.

Types Of Warehouse Forklifts

Be it a job site or a warehouse, and forklifts have become one of the most used and powerful tools in the industry. If you know how to operate the forklift truck, you will replace the manual labor and complete the task at hand with much more precision. As a result, warehouse owners have started thinking of forklifts as a necessity, and you are bound to get confused with the number of options available in the market. 

Here is a description of different warehouse forklifts and how you can use them in different situations.

Warehouse forklifts: These are some of the most common forklifts used in the warehouse. It looks like a golf cart and is easy to drive for anyone with prior forklift experience. The key features of the forklifts include a capacity of 1 to 5 tones in one go. Therefore, it can be put to best use for transporting items for short distances in the warehouse. If you own a warehouse with a large number of items in the inventory, then this is your best bet. It comes in handy for those who want to unload the trucks directly onto the transport forklifts.

Side loader: This side loader is generally found in steel service centers and manufacturing facilities with heavy and bulky items. Since the operation usually happens sideways, you can drive up alongside racks and load and unload without turning. Depending on the warehouse setting and the things you store, you can use a side loader for lifting heavy and prolonged objects like pipes and timber. It moves in the direction of the load that making the whole process relatively easy.

Counterbalance forklifts: Even though forklifts are pretty handy around the warehouse, you might want to be careful in accidents. One of the most common accidents occurs when you overload the vehicle to finish the job quickly. It may cause the whole machinery to topple over. The counterbalance forklifts are your safety net in this case. It comes with the weight at one end of the vehicle that counterbalances the other end. It is used in situations where the circle maneuvering around the warehouse is necessary.

Telehandler: it is also commonly known as a reach or telescopic forklift, mainly used to reach heights and place objects. It comes with an extendable arm that can typically reach heights the other types cannot usually go. A standard telehandler can lift 5,500 lbs of materials from up to 19 ft in the air. These material handling trucks are great for reaching into tight spaces and odd angles.

Industrial forklifts: heavy-duty forklifts work well in carrying out industrial loads. When you combine the performance of a telehandler and a warehouse forklift, you will get the industrial forklift as a result. It can take a heavy load of up to 30,000 lbs and can reach rugged heights and adjustable length. If the warehouse design and demand require something to put on top racks, then the Industrial forklift will be a must-have for you.

Forklift Safety Rules For Amateur Users

Before you begin working in a warehouse as an employee, there are certain skill sets that you must possess. One of these is to use the forklift with ease. There are many places wherein you can get on-job forklift training. Forklift and powered industrial trucks are a little complicated in use. Before anyone entrusts responsibility to you for managing the goods throughout the day, they would like to see that you master the forklift training. Here are a few safety rules as per the experts. 

Understanding the various kinds: There is continuous progress in the field of automated warehouses. People have come up with efficient systems that can easily replace manual labor and help in the upkeep of the warehouse. However, unless you can get with the program of operating the heavy machinery inside the warehouse, your services will soon be rendered useless.

First, you must understand the various types of forklifts available in the market. Even if you do not know the ways and means of operating them, basic knowledge helps in the selection process.

 

• Electric Motor Rider Trucks
• Electric Motor Narrow Aisle Trucks
• Electric Motor Hand Trucks or Hand/Rider
• Internal Combustion Engine Trucks with Solid/Cushion Tires
• Internal Combustion Engine Trucks with Pneumatic Tires
• Electrical and Internal Combustion Engine Tractors
• Rough Terrain Forklift Trucks 

Knowing the hazards and ways of preventing the same: some of the common risks can help prevent them from happening while you are on the job.

 

• Never keep an unsecured load on the forklift as it may fall and crash while riding to the aisle.
• Forklifts can tip off because of excess load and unmanaged driving. Hence, you must keep the maximum load in mind and distribute it evenly on the surface.
• Standing on the forks for loading and unlading is never a good idea.
• Do not miss the floor marks in the warehouse for the forklifts. 

Requirements or the training program: you must follow the protocol for the workplace and the city guidelines for getting the job in the warehouse. Think about the safety protocols and the requirements to run the warehouse safely. The employer should be able to provide practical and lecture training from time to time. It helps in keeping up with the latest in technology for the employees. For example, when you get a piece of new equipment in the workplace, it allows you to demonstrate the same for all employees so that they understand the working even if they are not going to use it. Providing a certificate for the training program helps build confidence and work experience for the employees. 

Daily check on the forklift: when you enter a forklift training program, the trainer will introduce you to the importance of keeping a daily statement on the machine. It would help if you started with inspecting all the forklifts in use before you begin the day and the end of it. It helps to rectify any mishandling during work hours. You should know how to oil and lubricate the various parts and maintain the tires. Check for any water, oil, or radiator leaks that may hamper the smooth functioning. The forks of the machine should be well aligned with the rest of the body. If they are cracked or misaligned, you will end up tipping the warehouse products while carrying them. Testing the critical parts like brake, horn, and the well-functioning steering wheel is essential. You can also create a stipulated path for the forklift with the help of tape. It helps in keeping the pedestrians off the bay.

Top 6 Advantages of Pallet Racking System In Warehouse

The vital component to making a highly functional warehouse is by adding pallet racks. For the uninitiated, pallet racks are material handling storage aid systems designed to store materials on pallets. Although there is a plethora of pallet racking, all types enable storage of palletized materials in horizontal rows with many levels. 

If we trace the history of the pallet racking system, racks came to light during the Second World War in tandem with the forklift, which made a colossal impact on material handling.

 

With the aid of a forklift, pallets of boxes could be transported hassle-free. Instead of men carrying each box onto a truck or ship, the forklift could be used to oscillate or move entire pallets of products faster. Forklifts were gradually enhanced to lift pallets, which gave rise to the pallet rack. In the second half of the 1920s, the first vertical pallet storage system became functional.

With time, things have changed, and unlike earlier times, the first pallet racks were able to hold only one layer of pallets, however, now the situation has altered. Manufacturers have devised ways of distributing the weight that permit multi-level pallet racks.

 

So, if you are unsure of why you need to add a racking system, then scroll ahead and unfold the top reasons to do so with us.

• Choice of sizes and price: Long-span shelving racks are available in a gamut of sizes and varied prices to fit your needs. The distinct types of pallet racks are Light, Open, Closed, and Heavy-Duty. Selective pallet racks are also commonly used and look-alike books arranged in a library.

• Enhanced productivity: Pallet storage aids you in organizing every item neatly. All staff can locate and configure the goods without any hassle. It also helps you to save time and skyrocket productivity.

• Prudent use of space: Space is a crucial factor to consider if you wish to expand your business. Pallet racks can help you to add space in your warehouse without splurging. This system ensures multiple goods are stored by utilizing a little extra floor space. Doubling or tripling the warehouse’s storage capacity is not a far-fetched idea. You can arrange pallet racks depending on the height of your warehouse or store. For instance, three or six pallets can be fitted in the footprint of one.

• Environmental-friendly Option: They make a conscious choice as they can be recycled, rebuild, and reused to plummet the landfill costs and wastage.

• Keep your employees safe: The safety of Employees is the responsibility of business leaders. Pallet racks can accelerate heavy stock capacity and hold goods safely and securely. The upright frames are sturdy, and the alternative bolt securing mechanism, or the popular teardrop design, makes the shelving immovable. You can also add netting to decrease the chances of items falling from a pallet. 

• Easy To Install: Warehouse storage should be easy to install as you may need to move pallet racks to distinct locations as your requirement. A warehouse is a fast-moving environment, and during a busy period, you may need to enhance your space-saving storage options by adding more pallet racking levels.

The Bottom Line  

In a nutshell, it would be correct to conclude that racks are user-friendly, enabling you to garner better revenue in the long run.

Racking Systems can make any business run smoother and saves from splurging. While choosing it, you need to comprehend the model and how it is perfect for your enterprise. Choose pallet racks made from high-quality material that meets all safety standards.

 

So, make sure to choose a copper-bottomed pallet racking supplier like Abel Womack. Our team will help you find the best model based on your complex business needs.

A Detailed Explanation on Warehouse Automation, Including Types and Benefits

Introduction

Automation is becoming more and more relevant in the modern world, and warehouses are no longer behind with warehouse automation becoming a more sensible option for warehouse operators and owners. Warehouse features such as forklifts, storage systems etc. are some areas that are automated. Cost-saving and efficiency are touted as the most comprehensive benefits of automating a warehouse, but there are also many other aspects on why warehouses should be automated as soon as possible.

What is Warehouse Automation?

Warehouse automation can be said as the process of automating the core elements of a warehouse such as inventory management, storage systems and retrieval systems that could be done with minimal intervention or assistance from human workers. While the exact elements to be automated depends on the project and end-goal of the project, inventory management is one of the first elements to be automated in any project.

What Changes Need to Be Done for a Warehouse Automation Project?

First of all, the existing systems needs to be evaluated. They have to be compatible with the automation systems or they are replaced with modern machines, which can increase the cost of the project. Secondly, the existing environment of the warehouse will require some changes due to introduction of computer and digital systems that act as controllers for automation systems. Thirdly, the new systems must be a lot more efficient, so planning needs to be done accordingly. Any changes made should reflect improvement in efficiency and not just be present for the sake of change.

Components of Warehouse Automation System

The components of a warehouse automation system can be divided into two major categories:

1. Digital Process Automation

2. Physical Process Automation

Digital process automation includes technological improvements such as warehouse management software, cloud-based database, machine learning algorithms, software applications, automation software etc. They consist of all the software that make the hardware and machines run properly and dictate the finer elements of automation.

Physical process automation includes robotic systems, automatic storage and retrieval systems, IoT systems, smart shelves, automated belts etc. They consist of all the hardware that are controlled by software in place.

How Does it Work?

The tasks that are to be automated are programmed into the automation software and other related software, which is then given out to hardware and machines such as robotics, sensors and storage systems. The entire system can be manually set up by the warehouse operators via central control system. Once the tasks are fed in, the system performs them exactly as specified continuously.

Types of Warehouse Automation

1. Simple Automation: It includes basic technology aimed at reducing human labor in warehouses, such as moving conveyor belts.

2. Digital Automation: It involves using computer software, such as analytics and machine learning, to improve warehouse efficiency using existing warehouse machinery in place.

3. Mechanized Automation: It involves using mechanical automation machines, such as robots or automatic storage systems that aim to improve warehouse efficiency and get more things done in much less time. Human workers work alongside these machines.

4. Fully Automated System: These combine both the software and hardware to achieve a complete automation of the warehouse where human involvement is minimal. Robotics and automated systems take care of all the essential daily tasks in the warehouse. This is implemented in most major high-volume warehouses across the country.

Main Benefits

1. High Efficiency: Machines are highly efficient and have nearly zero chance of error, helping the company save costs on downtime due to errors.

2. Adaptability: Automated warehouses can work with diverse workloads, reducing the load of increased demand or volume on the business.

3. Advanced Analytics: Automated warehouses allow for advanced analytics that provide companies on valuable data to improve the systems even more.

3. Better Consumer Satisfaction: High efficiency means consumers and clients get their goods delivered faster, increasing end-user satisfaction.

Benefits of using Pallet Conveyor in Industrial Settings

Conveyor systems are used across industries as a standard piece of mechanical handling equipment to move a wide range of products or goods, raw materials, and other materials from one location to another. While these were first invented to move products within the facility, however, they are now used in a variety of industries including, mining, agriculture, automotive, and the food and beverages industry. These machines handling equipment are extremely handy for businesses that deal with heavy goods, sharp items, raw materials, and mass-produced products.

As a piece of equipment, conveyor systems for pallet handling have revolutionized the industrial processes by not only speeding up the transportation of materials between long distances but also minimizing manual handling of materials by cutting down on human labor.

To fully, appreciate the uses, let's have a look at a few of its benefits and how they have modernized the processes of the industries, making the operations safer and more efficient.

Improves handling and processing operations
When conveyor systems are designed for pallet handling, the manufacturers deliver the perfect solutions for your facility that meets the particular regulations of production. Industries can put the conveyors into different floor plans and move depending on the volume of products. These portable conveyor systems have become popular in the logistics and parcel delivery industry, as without proper handling and ongoing operations it can be difficult to configure the number of parcels coming in or being moved to warehouses for distribution. When you know your needs and requirements beforehand, you can simply design the material flow exactly to your space availability.

High throughput capacity

When you deploy pallet conveyors in your existing system most often your focus is on increasing warehouses' cost-effectiveness and productivity. Being said that, before the use of conveyor systems, transporting materials from one level to another involved human labor that is not only slow, but this also forced companies to spare some of their revenue on labor. By choosing the right equipment, your operations will move in the best possible way resulting in high throughput speed in your warehouse.

Plus, you can save time when moving materials or products in different directions. Since conveyor systems eliminate manual unloading of materials, so there is no need to consume time monitoring loads and unloads every time the material moves in and out.

Cuts or in some cases eliminates manual labor cost

Manual material handling requires a lot of manpower. However, when it comes to conveyors, these require far less human intervention, and the employees you have will no longer have to manually carry heavy loads which can lead to injuries or workplace accidents that can cause serious injuries or unsatisfied orders. Conveyor systems allow the automated transportation of material between long distances that may be on varying elevations.

Flexibility and scalability

From small materials to delicate materials, the conveyor system can move just about any material between the pallets. Companies with decades of experience can help you choose the right conveyor technology applied in your warehouse based on the knowledge consulting with technicians and extensive process-related expertise. This ensures that you get a plant that complies with the standards of regulatory agencies. Moreover, allowing the industries to perfectly plan the systems that are ideally suited for their needs and are scalable when the need arises. As a result, businesses can greatly benefit from maximum flexibility and cost-effectiveness at the process level.

To get the maximum benefits, it is important to choose the right conveyor. Installing the wrong conveyor system will quickly undermine a warehouses' efficiency which will eventually lead to higher cost and lower customer satisfaction that no one wants. Selecting the right conveyor can be challenging for warehouse managers, however, when you collaborate with reputable companies you get the best possible configurations.

How Distribution Centers and Different Industries Can Benefit from Gravity Conveyors?

Having problems moving large volumes of items quickly and easily without manpower and mishandling?

As e-commerce sales continue to grow with people staying at home, the process of manufacturing and completing orders have become tighter and more demanding, which puts a lot of pressure on the distribution centers and warehouses for production and overall efficiency to transport the goods.

To reduce the amount of manual work and accidents that happened due to transportation of large, bulky and inconvenient materials and loads from one corner to another, many industries have adopted the use of conveyor systems over the past few decades. The use of gravity conveyors in the industry is similar to the typical conveyor system used, but these are used for a plethora of reasons. For instance, if you visit an airport, scrap yards, or a large factory, you will come across the conveyor system being used. When it comes to sifting large loads, moving across different directions, and working under dangerous and extreme conditions of loading and unloading, the industrial gravity conveyor system will be of great help.

If you want to keep up with the customers demands while cutting down the time that it takes to transport heavy items, finding the right distribution center gravity conveyor for your facility saves you time, hassle, and money and eases the overall stress with less effort and lower risk for workers handling heavy loads.

What are gravity conveyors?

Gravity conveyors are non-powered conveyors that help to move loads without utilizing motor power sources and only using the force of gravity to operate them. There is minimal manual force and with the help of incline, the materials and loads can easily move down the conveyor line. For instance, to transport products from one designated work area to a second work location a person pushes the load, and the materials with the help of gravity move down with the metal rollers and wheels.

These systems are often used in complex environments that require packaging, handling, loading, and offloading through racking systems due to their simplicity of design. Because of the benefits they provide, these conveyor systems are used in system aid in the safe transportation of material from one level to another which also helps to minimize the costs associated with employing human labor as well as buying costly equipment to move materials throughout the facility.

These potent conveyor machines are utilized to their full extent by every industry from material shipping to production. However, what is it that makes conveyor systems in industries so beneficial for the efficiency of work, and how the rise of the e-commerce industry is benefiting from these?

Let’s discover the benefits of conveyors in the distribution centers and how automation can benefit the characteristic of your production center and contribute maximum to the fulfillment of orders and customer satisfaction:

●   Requires minimal investment:

As mentioned, these require a bit of manual work, so there is no need to install expensive motors. A conveyor that runs on electricity also uses fuel or battery, each time the staff turns on the machine. Moreover, automated machines also have costs associated with maintenance and repairs. By utilizing a gravity conveyor, with fewer moving parts workers can carry large loads of any material easily.

●   It is a lot more efficient than automated conveyors:

When it comes to fuel and power consumption, the mechanism of gravity conveyor is a lot more efficient when businesses want to work during peak season making it possible to transport even more loads over a shorter period.

●   Increase in productivity and decrease in accidents:

These systems don’t require your employees to carry any item from one part of the facility to the other. They can simply put it on the system and transport it to any distance through the warehouse. This way integrating conveyors in the facility will reduce the lifting and lowers the risk of injury and on-site accidents that can happen due to transporting heavy loads.

Analyzing the Pros and Cons of Automated Storage & Retrieval Systems

Warehouse automation has picked up rapid pace over the past decade, mainly because of numerous technological advancements that have had an effect on warehouse management systems. One of the most important advancement is the introduction of automated storage & retrieval system that virtually eliminates the margin of error that may occur in case of a manual storage and retrieval system.

However, the technology requires a major installation process, and along with cost benefit analysis, many other factors need to be considered before a warehouse manager decides to install automated storage & retrieval systems in the warehouse. We shall be looking at the pros and cons of automated storage & retrieval systems to help managers make an informed decision about whether to go for the same or skip it.

Benefits of Automated Storage & Retrieval System

1. Better Safety

Safety is a primary area of concern for many warehouses, especially those warehouses that deal in storage and retrieval of heavy duty machinery parts. Accidents at workplaces are a major headache for the company involved who will have to shell out heavy medical bills and potential legal bills. Automated storage & retrieval systems help negate the risks by handling the essential tasks of storing an item and retrieving it, leaving the worker to only transport them across the warehouse, which has minimal risk of accident.

2. Reduction of Labor Costs

Companies are always looking for methods to cut down operating costs in the most efficient manner, and automated storage & retrieval systems are a great way to do so. They practically eliminate the labor costs that would have to be employed for manual storage & retrieval of items, which may lead to more money being spent on salaries which can get expensive for the company in the long run. Automated storage & retrieval systems basically require maintenance charges and electricity charges which, more often than not, cost far more less to the company as compared to human labor.

3. Highly Efficient and Productive

Installing an automated storage & retrieval system not only eliminates the need for labor in that area, but also makes the entire process highly efficient and productive. Machines can operate for 20-24 hours a day without breaks, and people can use their time for doing other productive tasks. Studies show that automated storage & retrieval systems can boost efficiency and productivity levels to almost twice their original level.

4. Minimal to No Errors in Operation

A major benefit of an automated storage & retrieval system is that they rarely make any kind of errors. The margin is very thin and often negligible, and this particular aspect is very important for high volume warehouses that store and shop thousands of packages in a single day. Working with so much volume means the scope of error has to be as low as possible, and automated storage & retrieval systems take care of that.

Cons Associated with Automated Storage & Retrieval System

1. High Initial Cost

Installing an automated storage & retrieval system requires high initial cost, which may not be feasible for many companies with low budget. However, this cost is later justified in the long run as the cost savings are much higher in future.

2. Technical Expertise Required

Operating an automated storage & retrieval system requires some level of technical skills, so the company will have to spend money on training existing employees on how to use them or hire experienced workers who can operate them and look after them.

3. Can Do Limited Tasks

Automated storage & retrieval systems don’t have a wide variety of tasks that they can do; they are capable of only generic storage and retrieval jobs with some degree of customization, so they cannot be put to use in environments that have a dynamic shift in operations on a daily basis.