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.

Understanding The Different Types Of Racking System In The Warehouse

While designing a warehouse or handling it as a business, you should know the intricacies. They can help you as a reference point in running it successfully. You will have to learn the types of equipment used in the warehouse and choose what you deem fit for your setup. Let us starts with understanding the racking system. Industrial racking system comprises metal structures that are designed to handle a different load of products. While choosing the perfect racking system for your business, you should first know the type of product you will keep in your warehouse.

The racking systems can be broadly classified into two categories, namely pallet racking and picking solutions. Pallet racking is meant for taking heavy loads of the warehouse products, and the picking racking system is intended for a lighter load.

The pallet racking system can be further divided into four categories:

Adjustable: Adjustable pallet racking system meant to cater to manual load. You can keep the goods in the aisle with the use of forklifts. Depending upon the width and accessibility of the products that you wish to store, you should decide between narrow racks and wide ones. As the name suggests, the former is for those who want to create a compact system and little room for unutilized space. This type of adjustable pallet racking is compacted by narrowing the aisles, resulting in a space-saving of over 40%. The minimum aisle width must be 1.5 m in this type of system.

As per this type of industrial system, the space utilization is more, but you will not have complete access to the material in one go. As the name suggests, it utilizes double depth in storing the products. Therefore, you can only use this racking system to invest in special forklifts equipped with telescopic forks or a pantograph mechanism to easily and quickly access the second pallet stored.

Mobile racking: This system consists of motors and remote traction elements to complete the stacking process. It helps in opening up only one aisle for work and storage at a time.

Compact racking: It is one of the most high-density storage systems that fully optimizes the workspace by reducing the truck aisle work to the maximum. These are automated structures where you can create parallel aisles inside the form.  The forklifts can quickly load and unload the products in these aisles. Even though you will not have direct access to all the products in the aisle, it is the best pick for the warehouses, where creating space is more important than access to each product. In other words, fast-running warehouses with a need for high storage are an ideal pick for this like of racking system. This racking system can be further classified into drive-in and drive-through systems.

Live pallet racking: Live pallet racking is a compact storage system that takes advantage of gravity forces and pushes to optimize pallet storage. You can use a slight incline and the pushing system to cover the areas that otherwise inaccessible. The loading and unloading area is created at the opposite ends, and it uses the first-in, first-out method to keep all the products in check. The other way is to have the same loading and unloading area wherein you can use the last-in, first-out method to gain access to the goods.

The racking systems can be broadly classified into two categories, namely pallet racking and picking solutions. Pallet racking is meant for taking heavy loads of the warehouse products, and the picking racking system is intended for a lighter load.

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 Warehouse Automation

Technology has taken over the work of manual labor away. It has struck the right chord with businesses that struggle with manual labor hiring all the time. One such space is the warehouse for big companies. There is so much to move in and out of the warehouse all the time that warehouse automation almost sounds like music to the ears. 

Imagine having heavy-duty machinery lifting the weight and getting the products to the right places without you having to worry about placement anymore. Even though it does not entirely take away the requirement for people, it does reduce the same by a substantial margin.

Categories for warehouse automation

Warehouse automation is a broad term. It has a lot of factors under the umbrella. You can either go for digital automation in your warehouse or opt for physical process automation. Each of them has its benefits, and you must weigh the pros and cons before you start investing in the options. With this, we explain a few categories for warehouse automation:

Basic warehouse automation: Basic automation uses planning and automation to reduce repetitive work and labor for people. Unlike the fully automated space, the basic automation allows you to use carousels and conveyor belts to get stuff from point A to B. You can use tools like warehouse forklifts for moving around the heavy load in the warehouse. It reduces the workload for people in the warehouse, and you can easily occupy them to get other work done.

Warehouse system automation: Gone are the days when the warehouse manager had to note the products in the various aisle and keep an inventory register for the things that move in and out. The warehouse system automation uses software, machine learning, robotics, and data analytics to automate tasks and procedures. The best part about keeping a management system in place is that it allows you to review all the orders in one go and match the inventory to the actuals at the end of the day. It takes away a lot of hassle that you would otherwise have to go through.

Mechanized warehouse automation: Every time you feel that technology has reached its peak with a product, be sure that the next one will take you by surprise again. A mechanized, automated warehouse is a perfect example of the premise above. It utilizes robotic equipment and systems to help humans in the warehouse work. The experts on the job essentially program the machinery so that you can shelf loader robots can pick up the desired products and deliver them to the human for further processing.

Advanced warehouse automation: These automation systems are designed to replace the labor-intensive human workflow in the warehouses. They combine the best from mechanized warehouse automation and other automated systems. It may still require human touch to operate and oversee the whole procedure, but you can finish the essential task with the help of robotic machines. They have sensors and cameras that can navigate the warehouse and scanners to help identify the product as and when the need arises. It is the best pick for the warehouses that have constant inflow and outflow of the products. Those who can invest in high-end machinery like a robotic forklift managing the warehouse will prove to be grateful.